Compressor (For 1Kd-Ftv) Installation

Temporarily install the cooler compressor with the 4 bolts.

HINT:

Tighten the bolts in the order shown in the illustration.

Tighten the 4 bolts.

Torque:

25 N*m{255 kgf*cm, 18 ft.*lbf}

NOTICE:

Tighten the bolts in the order shown in the illustration to install the cooler compressor.

Remove the attached vinyl tape from the 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}

Remove the attached vinyl tape from the 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}

Install the No. 1 viscous heater bracket with the 4 bolts.

Torque:

45 N*m{459 kgf*cm, 33 ft.*lbf}

Install the viscous with magnet clutch heater assembly with the 2 bolts.

Torque:

45 N*m{459 kgf*cm, 33 ft.*lbf}

Connect the water by-pass hose and water hose.

Using pliers, grip the claws of the clips and slide the 2 clips.

Connect the viscous heater connector.

Use the pulley set bolt of the tensioner to rotate the tensioner pulley clockwise, and then install the V belt.

NOTICE:

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

Check that the indicator mark of the V-ribbed belt tensioner (LandCruiser RM00000147501OX.html).

Install the compressor outlet elbow with the 2 bolts and tighten the hose clamp.

Torque:

for bolt:

20 N*m{204 kgf*cm, 15 ft.*lbf}

for hose clamp:

6.5 N*m{66 kgf*cm, 58 in.*lbf}

Install the wire harness bracket with the bolt.

Torque:

8.0 N*m{82 kgf*cm, 71 in.*lbf}

Attach the 3 wire harness clamps.

Install the air cleaner case sub-assembly with the 3 bolts.

Torque:

12 N*m{122 kgf*cm, 9 ft.*lbf}

Attach the 4 clamps to install the air cleaner cap sub-assembly.

except Cold Area Specification Vehicles:
Attach the 2 clamps and connect the mass air flow meter connector.

for Cold Area Specification Vehicles:
Attach the 3 clamps and connect the mass air flow meter connector.

Install the No. 1 air cleaner hose with the 2 hose clamps.

NOTICE:

1. When installing the No. 1 air cleaner hose, align the protrusion of the No. 1 air cleaner hose with the protrusion of the compressor inlet elbow as shown in the illustration.
   
2. When installing the No. 1 air cleaner hose, align the groove of the No. 1 air cleaner hose with the protrusion of the air cleaner cap as shown in the illustration.
   

Tighten the 2 hose clamps.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

NOTICE:

When tightening the 2 hose clamps, make sure that they are positioned as shown in the illustration.

Install the battery hold down clamp with the 2 nuts.

Torque:

6.0 N*m{61 kgf*cm, 53 in.*lbf}

Connect the No. 2 water by-pass hose to the radiator reservoir.

Connect the No. 1 water by-pass hose to the fan shroud and attach the 2 clamps.

Install the radiator reservoir assembly with the 3 bolts.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Tighten the radiator drain cock plug by hand.

Tighten the cylinder block drain cock plug.

Torque:

8.0 N*m{82 kgf*cm, 71 in.*lbf}

Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the B line of the reservoir tank.

Standard Capacity:

Item		Specified Condition
for Automatic Transmission	w/ Rear Heater	14.9 liters (15.7 US qts, 13.1 Imp. qts)
	w/o Rear Heater	13.1 liters (13.8 US qts, 11.5 Imp. qts)
for Manual Transmission	w/ Rear Heater	15.0 liters (15.8 US qts, 13.2 Imp. qts)
	w/o Rear Heater	13.2 liters (13.9 US qts, 11.6 Imp. qts)

HINT:

1. TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).
   
2. Please contact your TOYOTA dealer for further details.
   
3. for Cold Area Specification Vehicles:
   Please contact any authorized TOYOTA dealer or repairer or another duly qualified and equipped professional for further details.
   

NOTICE:

Never use water as a substitute for engine coolant.

Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
If the coolant level drops below the B line, add TOYOTA SLLC to the B line.

Install the radiator reservoir cap.

Using a wrench, install the vent plug.

Torque:

2.0 N*m{20 kgf*cm, 18 in.*lbf}

Bleed air from the cooling system.

1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.
   

2. Maintain the engine speed at 2500 to 3000 rpm.
   

3. Press the inlet and outlet radiator hoses several times by hand to bleed air.
   

   CAUTION:

   When pressing the radiator hoses:

   1. Wear protective gloves.
      
   2. Be careful as the radiator hoses are hot.
      
   3. Keep your hands away from the radiator fan.
      

4. Stop the engine and wait until the coolant cools down to ambient temperature.
   

   CAUTION:

   Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

After the coolant cools down, check that the coolant level is at the FULL line.
If the coolant level is below the FULL line, add TOYOTA SLLC to the FULL line.

Install the No. 1 engine under cover with the 4 bolts.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

Perform vacuum purging using a vacuum pump.

Charge refrigerant HFC-134a (R134a).

NOTICE:

1. Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.
   
2. Approximately 100 g (3.53 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.
   

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.

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

Perform the operation under these conditions:

1. Stop the engine.
   
2. Secure good ventilation (the halogen leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).
   
3. Repeat the test 2 or 3 times.
   
4. 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.

Install the upper radiator support seal with the 13 clips.