Compressor And Magnetic Clutch: Installation

ADJUST COMPRESSOR OIL
1. When replacing the compressor and magnetic clutch with a new one, gradually discharge the refrigerant gas from the service valve, and drain the following amount of oil from the new compressor and magnetic clutch before installation.
  Standard:
  
  (Oil capacity inside the new compressor and magnetic clutch: 130 + 15 cc (4.6 + 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)
  NOTE:
  - When checking the compressor oil level, observe the A/C system's precautions.
  - If a new compressor and magnetic clutch is installed without removing some 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 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 ND-OIL 8 or equivalent for compressor oil.
INSTALL COOLER COMPRESSOR ASSEMBLY
1. Install the cooler compressor with the 2 stud bolts
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
2. Install the 2 bolts and 2 nuts.
  Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf)
  
  NOTE: Tighten the nuts and bolts in the order shown in the illustration to install the cooler compressor.
3. Connect the connector.
Fig 1: Identifying Cooler Compressor Assembly Bolts And Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT DISCHARGE HOSE SUB-ASSEMBLY
1. Remove the attached vinyl tape from the hose.
2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor.
  Compressor oil: ND-OIL 8 or equivalent
3. Install the O-ring to the cooler refrigerant discharge hose.
4. Install the cooler refrigerant discharge hose to the cooler compressor with the bolt.
  Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf)
  
  Fig 2: Locating Discharge Hose Sub-Assembly Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT SUCTION HOSE SUB-ASSEMBLY
1. Remove the attached vinyl tape from the hose.
2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor.
  Compressor oil: ND-OIL 8 or equivalent
3. Install the O-ring to the cooler refrigerant suction hose.
4. Install the cooler refrigerant suction hose to the cooler compressor with the bolt.
  Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf)
  
  Fig 3: Locating Cooler Refrigerant Suction Hose Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY (for Bank 1) (See INSTALLATION )
INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (See INSTALLATION )
INSTALL POWER STEERING LINK ASSEMBLY
1. w/VGRS:
  Install the power steering link (see INSTALLATION ).
2. w/o VGRS:
  Install the power steering link (see INSTALLATION ).
INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
1. w/VGRS:
  Install the No. 2 steering intermediate shaft (see INSTALLATION ).
2. w/o VGRS:
  Install the No. 2 steering intermediate shaft (see INSTALLATION ).
INSTALL STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY
1. w/VGRS:
  Install the steering sliding with shaft yoke (see INSTALLATION ).
2. w/o VGRS:
  Install the steering sliding with shaft yoke (see INSTALLATION ).
INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH (See INSTALLATION )
INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH (See INSTALLATION )
INSTALL FRONT STABILIZER BAR (See INSTALLATION )
INSTALL REAR ENGINE UNDER COVER RH
INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY (See INSTALLATION )
INSTALL FRONT EXHAUST PIPE ASSEMBLY
1. Install the front exhaust pipe (see INSTALLATION ).
INSTALL ENGINE ROOM ECU OUTLET DUCT
1. Install the engine room outlet duct.
Fig 4: Identifying Outlet Duct
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR CLEANER ASSEMBLY RH (See INSTALLATION )
INSTALL AIR CLEANER CAP SUB-ASSEMBLY RH
INSTALL AIR CLEANER ASSEMBLY LH (See INSTALLATION )
INSTALL AIR CLEANER CAP SUB-ASSEMBLY LH
INSTALL FAN AND GENERATOR V BELT (See REMOVAL )
INSTALL INTAKE AIR CONNECTOR PIPE
INSTALL RADIATOR RESERVOIR ASSEMBLY
INSTALL NO. 1 AIR CLEANER INLET
INSTALL FRONT SUSPENSION CROSSMEMBER LOWER
1. Install the frame rail with the 6 bolts and 4 nuts.
  Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
  
  Fig 5: Locating Frame Rail Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR FRAME SIDE RAIL
1. Install the frame rail with the 6 bolts and 4 nuts.
  Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
INSTALL FRONT BUMPER COVER
1. Install the front bumper cover (see INSTALLATION ).
INSTALL RADIATOR SUPPORT OPENING COVER
INSPECT FOR EXHAUST GAS LEAK
INSTALL FRONT WHEEL
PLACE FRONT WHEELS FACING STRAIGHT AHEAD
CHECK AND ADJUST FRONT WHEEL ALIGNMENT
1. Check and adjust the front wheel alignment (see ADJUSTMENT ).
CHECK SHIFT LEVER POSITION
INSTALL FRONT SUSPENSION MEMBER PROTECTOR LOWER
1. Install the suspension member protector with the 8 bolts.
Fig 6: Locating Suspension Member Protector Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 ENGINE UNDER COVER
1. Install the under cover with the 8 bolts.
Fig 7: Locating Under Cover With Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 ENGINE UNDER COVER (See REPLACEMENT )
INSTALL V-BANK COVER SUB-ASSEMBLY
INSTALL ENGINE ROOM SIDE COVER RH

Fig 8: Locating Engine Room Side Cover Clips
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the side cover with the 4 clips.
INSTALL ENGINE ROOM SIDE COVER LH
1. Install the side cover with the 4 clips.
Fig 9: Locating Engine Room Side Cover Clips
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR CLEANER INLET COVER SUB-ASSEMBLY
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
INSTALL COWL TOP VENTILATOR LOUVER RH (See INSTALLATION )
ADD COMPRESSOR OIL (See REPLACEMENT )
CHARGE REFRIGERANT (See REPLACEMENT )
WARM UP ENGINE (See REPLACEMENT )
CHECK FOR LEAKAGE OF REFRIGERANT (See REPLACEMENT )
PERFORM INITIALIZATION
1. Perform initialization (see INITIALIZATION ).
  NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.