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Installation [10/2014 - ]: Procedure

  1. ADJUST COMPRESSOR OIL 
    1. When replacing the compressor with a new one:
      1. Remove the drain bolt (washer).
        GTY540005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *a Drain Bolt (Washer)
      2. Gradually discharge the inert gas from the service valve. Then drain the following amount of oil from the new compressor before installation so that the amount of oil contained in it is the same as that in the compressor to be replaced.
        GTY554158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        HINT: 

        New compressors are filled with sufficient oil for the whole air conditioning system. Therefore, it is necessary to drain oil from the new compressor to compensate for oil remaining in the condenser and cooling unit.

        TEXT IN ILLUSTRATION

        *a Removed Compressor
        *b Amount of oil to be drained from removed compressor
        *c Amount of oil remaining in the reserve chamber (60 cc (3.66 fl.oz))

        Standard

        (The amount of oil inside a new compressor: 100 (+15) cc (6.10 (+0.92) fl.oz)) - (The amount of oil remaining in the old compressor A + oil remaining in the reserve chamber: 60 cc (3.66 fl.oz)) = (The amount of oil to be removed when replacing the compressor)

        NOTE:
        • When A + 60 cc (3.66 fl.oz) exceeds the standard oil fill volume specified for the compressor by part number, install the compressor without adjusting the oil volume.

          Example:

          If A = 45 cc (2.75 fl.oz), A + 60 cc (3.66 fl.oz) = 105 cc (6.41 fl.oz). If the standard volume is 100 cc (6.10 fl.oz), install the compressor as is.

        • If the amount of oil remaining in the removed compressor is too low, check for oil leaks.
        • Use ND-OIL8 or equivalent for compressor oil.
      3. Install the drain bolt (washer).

        Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

    2. If draining the oil is difficult, drain the oil using the following procedure:
      1. Remove the suction seal cap.
      2. Lightly shake the compressor with the suction port facing down, and drain the oil (*1).
        GTY364730Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

        Do not allow the pulley to come into contact with the compressor oil.

    3. With the pulley facing down, rotate the hub in the direction shown by the arrow 10 times at a rate of approximately once every 2 seconds (*2).
      GTY364729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      WARNING:

      If the pulley is rotated, refrigerant or oil may spray out. Thus, keep your face away from the compressor port.

    4. Rotate the hub once in the direction shown by the arrow while quickly turning the compressor with the pulley facing up (*3).
      GTY364728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Perform step (*1) and drain the oil (*4).
    6. Drain the oil by repeating steps (*2) to (*4) approximately 5 times.
  2. INSTALL COMPRESSOR AND MAGNETIC CLUTCH 
    1. Install the compressor and magnetic clutch and bracket with the 4 bolts.
      Fig 1: Tightening Sequence Of Compressor And Magnetic Clutch And Bracket
      GTY571582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) 

      HINT: 

      Tighten the bolts in the order shown in the illustration to install the compressor and magnetic clutch.

    2. Engage the 3 clamps.
    3. Connect the 3 connectors.
  3. CONNECT SUCTION HOSE SUB-ASSEMBLY 
    1. Remove the vinyl tape from the suction hose sub-assembly and compressor and magnetic clutch.
    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch.

      Compressor Oil

      ND-OIL 8 or equivalent

    3. Install the O-ring to the suction hose sub-assembly.
    4. Connect the suction hose sub-assembly to the compressor and magnetic clutch with the bolt.

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

  4. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE 
    1. Remove the vinyl tape from the No. 1 cooler refrigerant discharge hose and compressor and magnetic clutch.
    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch.

      Compressor Oil

      ND-OIL 8 or equivalent

    3. Install the O-ring to the No. 1 cooler refrigerant discharge hose.
    4. Connect the No. 1 cooler refrigerant discharge hose to the compressor and magnetic clutch with the bolt.

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

  5. INSTALL V-RIBBED BELT 

    (Refer to INSTALLATION [10/2014 - ] )

  6. INSTALL RADIATOR ASSEMBLY 

    (Refer to INSTALLATION [10/2014 - ] )

  7. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    See step  2

  8. WARM UP ENGINE 

    See step  3

  9. INSPECT FOR REFRIGERANT LEAK 

    See step  4

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