Installation

AIR CONDITIONING: COMPRESSOR AND PULLEY (for 2AZ-FE): INSTALLATION

INSTALLATION

1. ADJUST COMPRESSOR OIL LEVEL





(a) When replacing the cooler compressor assembly with a new one, gradually discharge the inert gas (helium) from the service valve, and drain the following amount of oil from the vents indicated by the arrows in the illustration before installation.
HINT: The drain bolt and washer can be reused.

Standard:
AC (Oil capacity inside the new compressor and magnetic clutch: 160 + 15 cc (5.4 + 0.51 fl.oz.)) - (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed from the new compressor when replacing)
NOTICE:
- If a new compressor and magnetic clutch is installed without removing some oil, due to the oil remaining in the pipes of the vehicle, the oil amount will be too large. This prevents heat exchange in the refrigerant cycle and causes refrigeration system failure.
- If the volume of oil remaining in the removed compressor and magnetic clutch is too small, check for oil leakage.
- Be sure to use ND-OIL 8 or equivalent for compressor oil.

2. INSTALL COMPRESSOR AND PULLEY





(a) Install the compressor and pulley and the engine wire harness bracket with the 4 bolts.
Torque: 25 Nm (255 kgf-cm, 18ft-lbf)
NOTICE: Tighten the bolts in the order shown in the illustration to install the compressor and pulley.

3. INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE





(a) Remove the attached vinyl tape from the hose.
(b) Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch.
Compressor oil:
ND-OIL 8 or equivalent
(c) Install the O-ring onto the No. 1 cooler refrigerant suction hose.
(d) Install the No. 1 cooler refrigerant suction hose onto the compressor and magnetic clutch with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 87in-lbf)
4. INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE





(a) Remove the attached vinyl tape from the hose.
(b) Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch.
Compressor oil:
ND-OIL 8 or equivalent
(c) Install the O-ring onto the No. 1 cooler refrigerant discharge hose.
(d) Install the discharge hose sub-assembly onto the compressor and magnetic clutch with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 87in-lbf)
5. INSTALL PIPING CLAMP





(a) Install the piping clamp to the No. 1 cooler refrigerant suction hose and No. 1 cooler refrigerant discharge hose.
6. INSTALL GENERATOR ASSEMBLY Installation
7. INSTALL V-RIBBED BELT Installation
8. INSTALL FRONT FENDER APRON SEAL RH
9. INSTALL RADIATOR HOSE OUTLET





(a) Install the radiator hose outlet and attach the clip.
10. CONNECT BATTERY NEGATIVE TERMINAL
11. ADD ENGINE COOLANT Testing and Inspection
12. CHECK FOR ENGINE COOLANT LEAKS
NOTICE: Do not turn the A/C on before charging with refrigerant. Doing so will cause the cooler compressor to work without refrigerant, resulting in overheating of the cooler compressor.

13. INSTALL ENGINE UNDER COVER RH
14. INSTALL FRONT WHEEL RH
15. CHARGE WITH REFRIGERANT Service and Repair
16. WARM UP ENGINE Service and Repair
17. CHECK FOR REFRIGERANT LEAKS Service and Repair