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Installation [12/2019 - 10/2022]: Procedure

  1. ADJUST COMPRESSOR OIL 
    1. When replacing the compressor with a new one:
      1. Remove the drain bolt (seal washer).
        GTY693539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Drain Bolt (Seal 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.

        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.

        GTY452636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Removed Compressor
        *b Amount of oil to be drained from removed compressor
        *c Amount of oil remaining in the reserve chamber (60 cc (2.03 fl.oz))

        Standard

        (The amount of compressor oil inside a new compressor assembly with pulley: 120 (+15) cc (4.06 (+0.51) fl.oz)) - (The amount of compressor oil remaining in the removed compressor assembly with pulley) = The amount of compressor oil to be removed when replacing the compressor assembly with pulley.

        NOTE:
        • When A + 60 cc (2.03 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 (1.52 fl.oz), A + 60 cc (2.03 fl.oz) = 105 cc (3.55 fl.oz). If the standard volume is 120 cc (4.06 fl.oz), install the compressor as is.

        • If the amount of compressor oil remaining in the removed compressor assembly with pulley is too low, check for compressor oil leaks.
        • Make sure to use ND-OIL 12 or equivalent compressor oil.
      3. Install the drain bolt (seal 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 to drain the oil (*1).
        GTY719083Courtesy 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 as shown in the illustration 10 times at a rate of approximately once every 2 seconds (*2).
      WARNING:

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

      GTY719079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Rotate the hub once as shown in the illustration while quickly turning the compressor with the pulley facing up (*3).
      GTY719081Courtesy 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. Using an E8 "TORX" socket wrench, temporarily install the compressor and magnetic clutch with the 2 stud bolts.

      Torque: 4.0 N.m (41 kgf/cm, 35 in.lbf) 

    2. Install the compressor and magnetic clutch and bracket with the 2 bolts and 2 nuts.
      Fig 1: Compressor And Magnetic Clutch And Bracket Bolts And Nuts Tightening Sequence
      GTY922619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bracket
      Bolt
      Nut

      Torque: 24.5 N.m (250 kgf/cm, 18 ft.lbf) 

      HINT: 

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

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

      Compressor Oil

      ND-OIL 12 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 DISCHARGE HOSE SUB-ASSEMBLY 
    1. Remove the vinyl tape from the discharge hose sub-assembly.
    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the discharge hose sub-assembly.

      Compressor Oil

      ND-OIL 12 or equivalent

    3. Install the O-ring to the discharge hose sub-assembly.
    4. Connect the discharge hose sub-assembly 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 [12/2019 - 10/2022]

  6. INSTALL RADIATOR ASSEMBLY 

    Refer to INSTALLATION [12/2019 - 09/2020] , or refer to INSTALLATION [09/2020 - 10/2022]

  7. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 2

  8. WARM UP ENGINE 

    Refer to PROCEDURE - Step 3

  9. INSPECT FOR REFRIGERANT LEAK 

    Refer to PROCEDURE - Step 5

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