Compressor (For 5L-E) Installation

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

Standard:

(The amount of oil inside a new cooler compressor: 180 to 195 cc (6.1 to 6.6 fl. oz.)) - (The amount of oil remaining in the removed cooler compressor) = (The amount of oil to be removed when replacing the compressor)

NOTICE:

1. When checking the compressor oil level, follow the A/C system precautions.
   
2. Since compressor oil remains in the pipes of the vehicle, if a new compressor is installed without removing some oil from the compressor, the oil amount becomes excessive. Excessive oil prevents heat exchange in the refrigerant cycle and causes refrigeration system failure.
   
3. If the volume of oil remaining in the removed compressor is too small, check for oil leakage.
   
4. Be sure to use ND-OIL 8 for compressor oil.
   

Temporarily install the cooler compressor with the 2 bolts.

Temporarily install the idle pulley with the 4 bolts.

Tighten the 6 bolts in the sequence shown in the illustration.

Torque:

for bolt A:

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

except bolt A:

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

Connect the connector.

Remove the vinyl tape attached to the hose.

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

Compressor oil:

ND-OIL 8 or equivalent

Install the O-ring to the suction hose.

Connect the suction hose to the compressor with the bolt.

Torque:

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

Remove the vinyl tape attached to the hose.

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

Compressor oil:

ND-OIL 8 or equivalent

Install the O-ring to the discharge hose.

Connect the discharge hose to the compressor with the bolt.

Torque:

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

Install the V belt.

While tightening bolt B, adjust the tension of the V belt.

Tighten nut A.

Torque:

39 N*m{400 kgf*cm, 29 ft.*lbf}

Check the tension of the V belt (LandCruiser RM000001KYZ00GX_01_0001.html).

Install the air cleaner case with the 3 bolts.

Torque:

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

Insert the hinge part of the air cleaner cap and hose into the air cleaner case, and then attach the 4 hook clamps.

Connect the air cleaner cap sub-assembly with the clamp.

Torque:

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

Attach the wire harness clamp.

Connect the 2 clamps and connector.

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.