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Compressor And Magnetic Clutch: Installation

WARNING: This page is about a different car, the 2007 Toyota Tacoma. However, it is still accessible from the selected car via links, so may be relevant.
  1. ADJUST COMPRESSOR OIL 
    1. When replacing the compressor and magnetic clutch with new ones, after gradually discharging the refrigerant gas from the service valve, drain the following volume of oil from new compressor and magnetic clutch before installation.

      Standard: (Oil capacity inside a new compressor and magnetic clutch: 150 + 15 cc (5.1 + 0.51 fl.oz.)) - (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed when replacing the compressor) 

      NOTE:
      • When checking the compressor oil level, observe the precautions on the cooler removal/installation.
      • If a new compressor and magnetic clutch are installed without removing some oil remaining in the pipes of the vehicle, the oil amount becomes 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 RL-897 for compressor oil.
  2. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (for 2TR-FE) 
    1. Provisionally tighten the compressor and magnetic clutch with the 4 bolts and harness bracket.
      NOTE: The harness bracket stopper should be in contact with compressor case.
    2. Tighten the compressor and magnetic clutch with the 4 bolts.

      Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) 

      NOTE: Tighten the bolts in the sequence order shown in Fig 1 to install the compressor and magnetic clutch.
    3. Connect the connector.
      Fig 1: Installing Compressor & Magnetic Clutch With Bolts (2TR-FE)
      G04411511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (for 1GR-FE) 
    1. Provisionally tighten the compressor and magnetic clutch with the 4 bolts.
    2. Tighten the compressor and magnetic clutch with the 4 bolts.

      Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) 

      NOTE: Tighten the bolts in the sequence order shown in Fig 2 to install the compressor and magnetic clutch.
    3. Connect the connector.
      Fig 2: Installing Compressor & Magnetic Clutch With Bolts (1GR-FE)
      G04411512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL DISCHARGE HOSE SUB-ASSEMBLY 
    1. Remove the attached vinyl tape from the hose.
    2. Apply sufficient compressor oil to a new seal washer and fitting surface of the compressor and magnetic clutch.

      Compressor oil: RL-897 or equivalent 

    3. Install the seal washer onto the cooler refrigerant discharge hose sub-assembly.
    4. Install the cooler refrigerant discharge hose sub-assembly onto the compressor and magnetic clutch with the bolt.

      Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 

      Fig 3: Installing Cooler Refrigerant Discharge Hose Sub-Assembly Onto Compressor & Magnetic Clutch With Bolt
      G04411513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL SUCTION HOSE SUB-ASSEMBLY (for 2TR-FE) 
    1. Remove the attached vinyl tape from the hose.
    2. Apply sufficient compressor oil to a new seal washer and fitting surface of the compressor and magnetic clutch.

      Compressor oil: RL-897 or equivalent 

    3. Install the seal washer onto the suction hose sub-assembly.
    4. Install the suction hose sub-assembly onto the compressor and magnetic clutch with the bolt.

      Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 

    5. Install the suction hose sub-assembly with the bolt.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

      Fig 4: Installing Suction Hose Sub-Assembly Onto Compressor & Magnetic Clutch With Bolt (2TR-FE)
      G04411514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL SUCTION HOSE SUB-ASSEMBLY (for 1GR-FE) 
    1. Remove the attached vinyl tape from the hose.
    2. Apply sufficient compressor oil to a new seal washer and fitting surface of the compressor and magnetic clutch.

      Compressor oil: RL-897 or equivalent 

    3. Install the seal washer onto the suction hose sub-assembly.
    4. Install the suction hose sub-assembly onto the compressor and magnetic clutch with the bolt.

      Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 

      Fig 5: Installing Suction Hose Sub-Assembly Onto Compressor & Magnetic Clutch With Bolt (1GR-FE)
      G04411515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the suction hose sub-assembly with the bolt.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

  7. INSTALL FRONT FENDER APRON SEAL UPPER 
    1. Install the front fender apron seal upper with the 5 clips. (4WD, PRE RUNNER)
      Fig 6: Installing Front Fender Apron Seal Upper With Clips (4WD, Pre Runner)
      G04411516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the front fender apron seal upper with the 6 clips. (2WD)
  8. INSTALL GENERATOR ASSEMBLY (for 1GR-FE) (See  INSTALLATION  ) 
  9. INSTALL FAN AND GENERATOR V BELT (for 2TR-FE) (See  INSTALLATION  ) 
  10. INSPECT FAN AND GENERATOR V BELT (for 2TR-FE) (See  INSTALLATION  ) 
    Fig 7: Installing Front Fender Apron Seal Upper With Clips (2WD)
    G04411517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL FAN AND GENERATOR V BELT (for 1GR-FE) (See  INSTALLATION  ) 
  12. INSTALL FAN SHROUD (for 1GR-FE) (See  INSTALLATION  ) 
  13. INSTALL RADIATOR SUPPORT TO FRAME SEAL LH (for 1GR-FE) 
  14. INSTALL V-BANK COVER (for 1GR-FE) (See  INSTALLATION  ) 
  15. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (for 2TR-FE) (See  INSTALLATION  ) 
  16. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (for 1GR-FE) (See  INSTALLATION  ) 
  17. INSTALL FRONT WHEEL LH 

    Torque: 113 N*m (1152 kgf*cm, 83 ft.*lbf) 

  18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

    Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) 

  19. CHARGE REFRIGERANT (See  REPLACEMENT   ) 
  20. WARM UP ENGINE (See  REPLACEMENT   ) 
  21. CHECK FOR REFRIGERANT LEAKAGE (See  REPLACEMENT   ) 
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