Land Cruiser URJ200 URJ202 GRJ200 VDJ200 - HEATING / AIR CONDITIONING

ADJUST COMPRESSOR OIL

INSTALL COOLER COMPRESSOR ASSEMBLY

CONNECT SUCTION HOSE SUB-ASSEMBLY

CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

INSTALL FAN & GENERATOR V BELT

INSTALL FRONT FENDER APRON SEAL LH

CHARGE REFRIGERANT

WARM UP ENGINE

CHECK FOR REFRIGERANT GAS LEAK

INSTALL UPPER RADIATOR SUPPORT SEAL

COMPRESSOR (for 1UR-FE) - INSTALLATION

1. ADJUST COMPRESSOR OIL

When replacing the compressor and magnetic clutch with a new one, gradually discharge the refrigerant gas from the service valve, and drain the following amount of oil from the new compressor and magnetic clutch before installation.

Standard:
(Oil capacity inside the new compressor and magnetic clutch: 135 + 15 cc (4.6 + 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:

When checking the compressor oil level, follow the A/C system precautions.

If a new compressor and magnetic clutch is installed without removing some 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 refrigerant 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 compressor oil.

2. INSTALL COOLER COMPRESSOR ASSEMBLY

Compressor (For 1Ur-Fe) - Installation. HEATING / AIR CONDITIONING. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Install the cooler compressor and stud bolt.

Torque:
10 N*m{ 102 kgf*cm, 7 ft.*lbf}

Install the 3 bolts and nut.

Torque:
24.5 N*m{ 250 kgf*cm, 18 ft.*lbf}

HINT:

Tighten the bolts and nut in the order shown in the illustration.

Connect the connector.

3. CONNECT SUCTION HOSE SUB-ASSEMBLY

Remove the attached vinyl tape from the suction hose.

Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor.

Compressor oil:
ND-OIL 8 or equivalent

Install the O-ring to the suction hose.

Connect the suction hose to the cooler compressor with the bolt.

Torque:
9.8 N*m{ 100 kgf*cm, 87 in.*lbf}

4. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

Remove the attached vinyl tape from the cooler refrigerant discharge hose.

Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor.

Compressor oil:
ND-OIL 8 or equivalent

Install the O-ring to the discharge hose.

Connect the discharge hose to the cooler compressor with the bolt.

Torque:
9.8 N*m{ 100 kgf*cm, 87 in.*lbf}

5. INSTALL FAN & GENERATOR V BELT

Set the fan and generator V belt onto every part.

Text in Illustration
*1	Water Pump Pulley
*2	Fan Pulley
*3	No. 1 Idler Pulley
*4	Vane Pump Pulley
*5	Generator Pulley
*6	V-ribbed Belt Tensioner
*7	Crankshaft Pulley
*8	Cooler Compressor Pulley

While turning the belt tensioner counterclockwise, remove the pin.

NOTICE:

Make sure that the fan and generator V belt is properly set on each pulley.

Check that the belt fits properly in the ribbed grooves.

HINT:

Make sure to check by hand that the belt has not slipped out of the grooves on the bottom of the pulley.

6. INSTALL FRONT FENDER APRON SEAL LH

Install the seal with the 4 clips.

7. CHARGE REFRIGERANT

SST
09985-20010(09985-02130,09985-02150,09985-02090,09985-02110,09985-02010,09985-02050,09985-02060,09985-02070)

Perform vacuum purging using a vacuum pump.

Charge refrigerant HFC-134a (R134a).

Standard:
Condenser Core Thickness	Air Conditioning Type	Cool Box	Refrigerant Charging Amount
22 mm (0.866 in.)	w/o Rear Cooler	w/ Cool Box	870 +/-30 g (30.7 +/-1.1 oz.)
	w/o Rear Cooler	w/o Cool Box	870 +/-30 g (30.7 +/-1.1 oz.)
	w/ Rear Cooler	w/ Cool Box	1010 +/-30 g (35.6 +/-1.1 oz.)
	w/ Rear Cooler	w/o Cool Box	960 +/-30 g (33.9 +/-1.1 oz.)
16 mm (0.630 in.)	w/o Rear Cooler	w/ Cool Box	770 +/-30 g (27.2 +/-1.1 oz.)
	w/o Rear Cooler	w/o Cool Box	770 +/-30 g (27.2 +/-1.1 oz.)
	w/ Rear Cooler	w/ Cool Box	970 +/-30 g (34.2 +/-1.1 oz.)
	w/ Rear Cooler	w/o Cool Box	920 +/-30 g (32.5 +/-1.1 oz.)

Compressor (For 1Ur-Fe) - Installation. HEATING / AIR CONDITIONING. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

NOTICE:

Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.

Approximately 200 g (7.05 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.

8. WARM UP ENGINE

Warm up the engine at less than 1850 rpm for 2 minutes or more after charging the refrigerant.

NOTICE:

Be sure to warm up the compressor when turning the A/C switch is on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

9. CHECK FOR REFRIGERANT GAS LEAK

After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.

Perform the operation under these conditions:

Stop the engine.

Secure good ventilation (the halogen leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).

Repeat the test 2 or 3 times.

Make sure that some refrigerant remains in the refrigeration system. When compressor is off: approximately 392 to 588 kPa (4.0 to 6.0 kgf/cm², 57 to 85 psi).

Using a halogen leak detector, check the refrigerant line for leakage.

If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the halogen leak detector sensor into the unit and perform the test.

Disconnect the connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test.

10. INSTALL UPPER RADIATOR SUPPORT SEAL

Install the radiator support seal with the 7 clips.

Compressor (For 1Ur-Fe) - Installation. HEATING / AIR CONDITIONING. Land Cruiser URJ200 URJ202 GRJ200 VDJ200