Compressor And Magnetic Clutch (For 5L-E) Installation

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

Standard:

(Oil capacity inside new compressor: 80 + 15 cc (2.7 + 0.5 fl. oz.)) - (Remaining oil amount in the removed compressor) = (Oil amount to be removed when replacing)

NOTICE:

1. When checking the compressor oil level, follow the A/C system's precautions.
   
2. Since compressor oil remains in the pipes of the vehicle, do not install a new compressor without removing some oil from the vehicle. Excessive oil prevents heat exchange in the refrigerant cycle and causes refrigerant failure.
   
3. If the remaining oil in the removed compressor is too low, check for oil leakage.
   
4. Be sure to use ND-OIL 8 for compressor oil.
   

Install the compressor with the 4 bolts and tighten the bolts in the order shown in the illustration.

Torque:

24.5 N*m{250 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 on the suction hose.

Torque:

9.8 N*m{100 kgf*cm, 7 ft.*lbf}

Connect the suction hose to the compressor with the bolt.

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 on the discharge hose.

Torque:

9.8 N*m{100 kgf*cm, 7 ft.*lbf}

Connect the discharge hose to the compressor with the bolt.

Install the V belt.

Tightening bolt B, adjust the deflection of the V belt (Toyota Fortuner RM000001KYZ001X_01_0001.html).

Tighten nut A.

Torque:

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

Recheck the deflection of the V belt.

Install the cleaner with the 2 bolts.

Torque:

14 N*m{143 kgf*cm, 10 ft.*lbf}

Connect the connector to the IAT sensor.

Connect the hose clamp.

Perform vacuum purging using a vacuum pump.

Charge refrigerant HFC-134a (R134a).

Standard:

450 +-30 g (15.87 +-1.05 oz.)

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 quantity, and not with the sight glass.
   

After recharging the refrigerant gas, prepare the vehicle for a refrigerant gas leakage check by making sure the following conditions are met.

1. The ignition switch is OFF.
   
2. The vehicle is in a place with good air ventilation and without any volatile gases, such as evaporated gasoline or exhaust gas. The detector is very sensitive to volatile gases. If volatile gases are unavoidable, the vehicle must be lifted up.
   
3. Some refrigerant remains in the refrigerant system.
   
4. The compressor is OFF and its pressure is approximately 392 to 588 kPa (4 to 6 kgf/cm²).
   

Check for refrigerant gas leakage from the refrigerant line.

1. After the blower motor stops, wait at least 15 minutes.
   

2. Using a halogen leak detector, check that gas is not leaking from the refrigerant line. If leakage is found, tighten parts or replace damaged parts as necessary to stop the leak.
   

Check for refrigerant gas leakage from the cooling unit.

1. Hold the halogen leak detector so that the sensor is under the drain hose, as shown in the illustration.
   

2. Check that gas is not leaking from the drain hose. If leakage is found, tighten parts or replace damaged parts as necessary to stop the leak.
   

Check for refrigerant gas leakage from the cooling unit.

1. Remove the blower motor control from the unit. Insert the halogen leak detector's sensor into the unit.
   

2. Check that gas is not leaking from the unit. If leakage is found, tighten parts or replace damaged parts as necessary to stop the leak.
   

Check for refrigerant gas leakage from the pressure switch.

1. Disconnect the pressure switch connector and wait approximately 20 minutes.
   

2. Using a halogen leak detector, check that gas is not leaking from the pressure switch. If leakage is found, tighten parts or replace damaged parts as necessary to stop the leak.
   

Repeat all the steps above 2 to 3 times.