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W/Pulley Compressor ASSY: Replacement

  1. DISCONNECT NEGATIVE TERMINAL CABLE FROM BATTER 
  2. EVACUATE REFRIGERANT HFC-134A (R134A) (SEE  REPLACEMENT  ) 
  3. REMOVE AIR CLEANER INLET NO.1 (SEE  REPLACEMENT  ) 
  4. REMOVE FAN AND GENERATOR V BELT (SEE  REPLACEMENT  ) 
  5. REMOVE ENGINE UNDER COVER NO.1 
  6. DISCONNECT COOLER REFRIGERANT DISCHARGE HOSE NO.1 
    1. Remove the nut and disconnect the cooler refrigerant discharge hose No.1.
    2. Remove the O-ring from the cooler refrigerant discharge hose No.1.
      NOTE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
      Fig 1: Locating Nut Cooler Refrigerant Discharge Hose
      G01029481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO.1 
    1. Remove the bolt and disconnect the cooler refrigerant suction hose No.1.
    2. Remove the O-ring from the cooler refrigerant suction hose No.1.
      NOTE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
      Fig 2: Locating Bolt Cooler Refrigerant Suction Hose
      G01029482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE COMPRESSOR MOUNTING BRACKET NO.1 
    1. Remove the bolt, nut and compressor mounting bracket No.1.
      Fig 3: Locating Bolt And Nut Compressor Mounting Bracket
      G01029483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE W/PULLEY COMPRESSOR ASSY 
    1. Disconnect the connector.
    2. Remove the 2 bolts and w/pulley compressor assy.
      Fig 4: Locating Bolts W/Pulley Compressor Assy
      G01029484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. ADJUST COMPRESSOR OIL 
    1. When replacing the compressor and magnetic clutch with a new one, after gradually removing the refrigerant gas from the service valve, drain the following amount of oil from the new compressor and magnetic clutch before installation.

      Standard: 

      (Oil capacity inside the new compressor: 130+15 cc (4.4+0.5 fl.oz)) - (Remaining oil amount in the removed compressor) = (Oil amount to be removed from the new compressor when replacing) 

      NOTE:
      • When checking the compressor oil level, observe the precautions on the air conditioning radiator assy removal/installation.
      • Because compressor oil remains in the pipes of the vehicle, if a new compressor and magnetic clutch is installed without removing some oil inside, the oil amount becomes too much, preventing heat exchange in the refrigerant cycle and causing refrigerant failure.
      • If the remaining oil in the removed compressor and magnetic clutch is too small in volume, check for oil leakage.
      • Be sure to use ND-OIL 8 or equivalent for compressor oil.
  11. TEMPORARILY TIGHTEN W/PULLEY COMPRESSOR ASSY 
    1. Temporarily tighten the w/pulley compressor assy with the 2 bolts.
    2. Connect the connector.
      Fig 5: Locating Bolts W/Pulley Compressor Assy
      G01029485Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL COMPRESSOR MOUNTING BRACKET NO.1 
    1. Install the compressor mounting bracket No.1 with the bolt and nut.

      Torque: 

      Bolt: 49 N.m (500 kgf.cm, 36ft.lbf)

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

      Fig 6: Locating Bolts Compressor Mounting Bracket
      G01029486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. FULLY TIGHTEN W/PULLEY COMPRESSOR ASSY 
    1. Fully tighten the w/pulley compressor assy with the 2 bolts.

      Torque:49 N.m (500 kgf.cm,36 ft.lbf) 

      Fig 7: Locating Bolts Compressor Assy
      G01029487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 
    1. Remove the attached vinyl tape from the hose.
    2. Sufficiently apply compressor oil to the new O-ring and fitting surface of the compressor and magnetic clutch.

      Compressor oil: ND-OIL 8 or equivalent 

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

      Torque: 9.8 N.m (100 kgf.cm,7 ft.lbf) 

      Fig 8: Locating Bolt Cooler Refrigerant Suction Hose
      G01029488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO.1 
    1. Remove the attached vinyl tape from the hose.
    2. Sufficiently apply compressor oil to the new O-ring and fitting surface of the compressor and magnetic clutch.

      Compressor oil: ND-OIL 8 or equivalent 

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

      Torque: 9.8 N.m (100 kgf.cm, 7 ft.lbf) 

      Fig 9: Locating Nut Cooler Refrigerant Discharge Hose
      G01029489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL FAN AND GENERATOR V BELT (SEE  REPLACEMENT  ) 
  17. INSTALL AIR CLEANER INLET NO.1 (SEE  REPLACEMENT  ) 
  18. CONNECT NEGATIVE TERMINAL CABLE TO BATTERY 
  19. CHARGE REFRIGERANT (SEE  REPLACEMENT  ) 
  20. WARM UP ENGINE 
  21. INSPECT FOR REFRIGERANT LEAKAGE (SEE  REPLACEMENT  ) 
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