Compressor And Pulley (For 2Az-Fe) Installation

When replacing the cooler compressor assembly with a new one, gradually discharge the inert gas (helium) from the service valve, and drain the following amount of oil from the vents indicated by the arrows in the illustration before installation.

HINT:

The drain bolt and washer can be reused.

Standard:

AC (Oil capacity inside the new compressor and magnetic clutch: 160 + 15 cc (5.4 + 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:

1. If a new compressor and magnetic clutch is installed without removing some oil, due to the 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 refrigeration system failure.
   
2. If the volume of oil remaining in the removed compressor and magnetic clutch is too small, check for oil leakage.
   
3. Be sure to use ND-OIL 8 or equivalent for compressor oil.
   

Install the compressor and pulley and the engine wire harness bracket with 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 compressor and pulley.

Remove the attached vinyl tape from the hose.

Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch.

Compressor oil:

ND-OIL 8 or equivalent

Install the O-ring onto the No. 1 cooler refrigerant suction hose.

Install the No. 1 cooler refrigerant suction hose onto the compressor and magnetic clutch with the bolt.

Torque:

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

Remove the attached vinyl tape from the hose.

Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch.

Compressor oil:

ND-OIL 8 or equivalent

Install the O-ring onto the No. 1 cooler refrigerant discharge hose.

Install the discharge hose sub-assembly onto the compressor and magnetic clutch with the bolt.

Torque:

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

Install the piping clamp to the No. 1 cooler refrigerant suction hose and No. 1 cooler refrigerant discharge hose.

Confirm that the wire harness of the crankshaft position sensor is secured to the wire harness clamp bracket through the back of the rib of the timing chain cover.

Install the generator assembly with the 2 bolts.

Torque:

Bolt A:

21 N*m{215 kgf*cm, 16 ft.*lbf}

Bolt B:

52 N*m{530 kgf*cm, 38 ft.*lbf}

Install the generator wire to terminal B with the nut.

Torque:

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

Install the clamp bracket with the bolt.

Torque:

8.4 N*m{86 kgf*cm, 74 in.*lbf}

Attach the clamp and connect the generator connector to the generator.

Using SST and 19 mm socket wrench, loosen the V-ribbed belt tensioner arm clockwise, then install the V-ribbed belt.

SST

09216-42010

NOTICE:

1. Be sure to connect SST and the tools so that they are in line during use.
   
2. When retracting the tensioner, turn it clockwise slowly for 3 seconds or more. Do not apply force rapidly.
   
3. After the tensioner is fully retracted, do not apply force any more than necessary.
   

After installing the V-ribbed belt, check that it fits properly in the ribbed grooves. Check to confirm that the belt has not slipped out of the grooves on the bottom of the crank pulley by hand.

Install the radiator hose outlet and attach the clip.

Close the radiator drain cock plug and 2 cylinder block drain cock plugs.

Torque:

13 N*m{130 kgf*cm, 9 ft.*lbf} for cylinder block drain cock plug

Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

Specified capacity:

6.2 liters (6.6 US qts, 5.5 lmp. 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).
   

1. Contact your TOYOTA dealer for further details.
   

Slowly pour coolant into the radiator reservoir tank until it reaches the FULL line.

Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
If the coolant level is low, add coolant.

Install the radiator cap sub-assembly and reservoir tank cap.

Start the engine, and warm it up.

HINT:

Adjust the air conditioner set temperature to MAX (HOT).

Stop the engine, and wait until the engine coolant cools down.

Add engine coolant to the FULL line on the radiator reservoir.

Perform vacuum purging using a vacuum pump.

Charge with refrigerant HFC-134a (R134a).

Standard:

450 to 550 g (15.9 to 19.4 oz.)

SST

07110-58060(07117-58060,07117-58070,07117-58080,07117-58090,07117-78050,07117-88060,07117-88070,07117-88080)

NOTICE:

1. Do not turn the A/C on before charging with refrigerant. Doing so will cause the cooler compressor to work without refrigerant, resulting in overheating of the cooler compressor.
   
2. Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear.
   The refrigerant amount should be checked by quantity, not with the sight glass.
   

HINT:

Ensure that sufficient refrigerant is available to recharge the system when using a refrigerant recovery unit. Refrigerant recovery units are not always able to recover 100 % of the refrigerant from an A/C system.

Keep the A/C switch on for at least 2 minutes to warm up the compressor.

NOTICE:

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

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

Carry out the test under the following conditions:

1. IG OFF
   
2. Secure good ventilation (the gas leak detector may react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas).
   
3. Repeat the test 2 or 3 times.
   
4. Make sure that there is some refrigerant remaining in the refrigeration system.
   When the compressor is off: approx. 392 to 588 kPa (4 to 6 kgf/cm², 57 to 85 psi)
   

Using a gas leak detector, check for leakage from the refrigerant lines.

Bring the gas leak detector close to the drain hose with the detector's power off, and then turn the detector on.

HINT:

1. After the blower motor has stopped, let the cooling unit stand for more than 15 minutes.
   
2. Bring the gas leak detector sensor under the drain hose.
   
3. When bringing the gas leak detector close to the drain hose, make sure that the gas leak detector does not react to volatile gases.
   If it is not possible to avoid interference from volatile gases, the vehicle should be lifted up to allow testing.
   

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

Disconnect the pressure switch connector and leave it for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test.