COMPRESSOR (for 2TR-FE) INSTALLATION


  1. ADJUST COMPRESSOR OIL


    1. When replacing the compressor and magnet 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 magnet clutch before installation.

      Standard
      (Oil capacity inside the new compressor and magnet clutch: 180 + 15 cc (6.08 + 0.51 fl.oz.)) - (Remaining oil amount in the removed compressor and magnet clutch) = (Oil amount to be removed from the new compressor)

      Note


      • When checking the compressor oil level, follow the A/C system precautions.

      • 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.

      • If the volume of oil remaining in the removed compressor and magnet clutch is small, check for oil leakage.

      • Be sure to use ND-OIL 8 or equivalent compressor oil.

  2. INSTALL COOLER COMPRESSOR ASSEMBLY


    1. A00XHZ5E01

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

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

    2. Connect the connector.

  3. INSTALL SUCTION HOSE SUB-ASSEMBLY


    1. Remove the vinyl tape attached to the hose.

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

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the suction hose.

    4. Connect the suction hose with the bolt.

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

  4. INSTALL DISCHARGE HOSE SUB-ASSEMBLY


    1. Remove the vinyl tape attached to the hose.

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

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the discharge hose.

    4. Connect the discharge hose with the bolt.

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

  5. CONNECT VANE PUMP ASSEMBLY


    1. Connect the vane pump with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    2. Connect the 2 connectors.

    3. Install the pressure feed tube with the bolt.

      Torque:
      28 N*m  { 285 kgf*cm, 21 ft.*lbf }

  6. INSTALL FAN SHROUD


    1. Install the fan pulley to the water pump.

    2. Place the shroud together with the coupling fan between the radiator and engine.

      Note

      Be careful not to damage the radiator core.

    3. Temporarily install the fluid coupling fan to the water pump with the 4 nuts. Tighten the nuts as much as possible by hand.

    4. A009ABC

      Attach the claws of the shroud to the radiator as shown in the illustration.

    5. Install the shroud with the 2 bolts.

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

    6. Install the fan and generator V-belt Click here.

    7. Tighten the 4 nuts of the fluid coupling fan.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
    8. A0098GD

      Attach the claw to close the flexible hose clamp as shown in the illustration.

  7. INSTALL NO. 2 RADIATOR HOSE


    1. A0094WOE01
      Text in Illustration
      *a Upper
      *b LH Side
      *1 Paint Mark

      Connect the No. 2 radiator hose to the radiator.

      Tech Tips

      Make sure the direction of the hose clamp is as shown in the illustration.

  8. INSTALL NO. 1 RADIATOR HOSE


    1. A009B81E01
      Text in Illustration
      *a Upper
      *b RH Side
      *1 Paint Mark

      Connect the No. 1 radiator hose to the radiator.

      Tech Tips

      Make sure the direction of the hose clamp is as shown in the illustration.

  9. INSTALL RADIATOR RESERVOIR


    1. Install the radiator reservoir with the 3 bolts.

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

    2. Connect the reservoir hose to the radiator.

  10. INSTALL FAN AND GENERATOR V BELT


    1. A00XCIJE01
      Text in Illustration
      *1 Crankshaft Pulley
      *2 Idler Pulley
      *3 Cooler Compressor
      *4 Fan Pulley
      *5 Vane Pump
      *6 No. 1 Idler Pulley
      *7 Generator
      *8 Belt Tensioner

      Install the V belt to all the pulleys except the drive belt tensioner pulley.

    2. Use the hexagonal part indicated by the arrow in the illustration to move the tensioner pulley downward and install the V belt to the tensioner pulley.

      Note


      • The backside of the V belt should face the tensioner pulley.

      • Check that the V belt is properly set on each pulley.

  11. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. A00O712

      Hook the engine under cover to the vehicle body as shown in the illustration.

    2. Install the 4 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  12. INSTALL FRONT BUMPER COVER LOWER


    1. Install the front bumper cover lower with the 5 bolts and clip.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  13. CHARGE REFRIGERANT

    SST
    09985-20010   ( 09985-02130, 09985-02150, 09985-02090, 09985-02110, 09985-02010, 09985-02050, 09985-02060, 09985-02070 )

    1. Perform vacuum purging using a vacuum pump.

    2. Charge refrigerant HFC-134a (R134a).

      Standard
      Model Code Air Conditioning Type Cool Box Refrigerant Charging Amount
      Except the model codes below w/o Rear Cooler w/ Cool Box 600 +/-30 g (21.2 +/-1.1 oz.)
      w/o Cool Box 550 +/-30 g (19.3 +/-1.1 oz.)
      w/ Rear Cooler w/ Cool Box 800 +/-30 g (28.2 +/-1.1 oz.)
      w/o Cool Box 770 +/-30 g (27.2 +/-1.1 oz.)

      w/ Rear Cooler

      for Cold Area Specification Vehicles

      		 w/o Cool Box 720 +/-30 g (25.3 +/-1.1 oz.)

      TRJ150L-GKMEKV

      TRJ150L-GKPEKV

      TRJ155L-GJPEKV

      GRJ150L-GKFEKV

      GRJ150L-GKAEKV

      KDJ150L-GKFEYV

      KDJ150L-GKAEYV

      		 w/o Rear Cooler w/ Cool Box 600 +/-30 g (21.2 +/-1.1 oz.)
      w/o Cool Box 550 +/-30 g (19.3 +/-1.1 oz.) or 600 +/-30 g (21.2 +/-1.1 oz.) *1
      w/ Rear Cooler w/ Cool Box 800 +/-30 g (28.2 +/-1.1 oz.)
      w/o Cool Box 770 +/-30 g (27.2 +/-1.1 oz.)

      *1: For vehicles with the 2TR-FE engine which have neither the rear cooler nor cool box, the refrigerant charging amount changes based on region.

      A00JY00E19

      Note


      • Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.

      • 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.

  14. ADD ENGINE COOLANT


    1. Tighten the cylinder block drain cock plug.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    2. Tighten the radiator drain cock plug by hand.

    3. Disconnect the 2 vinyl hoses.

    4. Add engine coolant.

      Standard Capacity
      Item Specified Condition
      for Automatic Transmission w/o Rear Heater 8.1 liters (8.6 US qts, 7.1 Imp. qts)
      w/ Rear Heater 9.9 liters (10.5 US qts, 8.7 Imp. qts)
      for Manual Transmission w/o Rear Heater 8.3 liters (8.8 US qts, 7.3 Imp. qts)
      w/ Rear Heater 10.1 liters (10.7 US qts, 8.9 Imp. qts)

      Note

      Do not substitute plain water for engine coolant.

      Tech Tips


      • 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).

      • Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the coolant level. If the coolant level is low, add coolant.

    5. Slowly pour coolant into the radiator reservoir until it reaches the F line.

    6. Install the reservoir cap.

    7. Install the radiator cap.*1

    8. Start the engine and stop it immediately.*2

    9. Allow approximately 10 seconds to pass. Then remove the radiator cap and check the coolant level. If the coolant level has decreased, add coolant.*3

    10. Repeat steps *1, *2 and *3 until the coolant level does not decrease.

      Tech Tips

      Be sure to perform this step while the engine is cold, as air in the No. 1 radiator hose will flow into the radiator if the engine is warmed up and the thermostat opens.

    11. Install the radiator cap.*4

    12. Set the air conditioning as follows.*5

      Item Condition
      Fan speed Any setting except off
      Temperature Toward WARM
      Air conditioning switch Off

    13. Start the engine, warm it up until the thermostat opens, and then continue to run the engine for several minutes to circulate the coolant.*6

      CAUTION:


      • Wear protective gloves. Hot areas on the parts may injure your hands.

      • Be careful of the fan.

      • Be careful as the engine, radiator and radiator hoses are hot and can cause burns.

      Note


      • Immediately after starting the engine, if the radiator reservoir does not have any coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the coolant is filled to the F line.

      • Do not start the engine when there is no coolant in the radiator reservoir.

      • Pay attention to the needle of the engine coolant temperature receiver gauge. Make sure that the needle does not show an abnormally high temperature.

      • If there is not enough coolant, the engine may burn out or overheat.

      Tech Tips


      • Press the No. 1 and No. 2 radiator hoses several times by hand to bleed air while warming up the engine.

      • The thermostat opening timing can be confirmed by pressing the No. 2 radiator hose by hand and checking when the engine coolant starts to flow inside the hose.

    14. Stop the engine, wait until the engine coolant cools down to ambient temperature. Then remove the radiator cap and check the coolant level.*7

      CAUTION:

      Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    15. If the coolant level has decreased, add coolant and warm up the engine until the thermostat opens.*8

    16. If the coolant level has not decreased, check that the coolant level in the radiator reservoir is at the F line.

      If the coolant level is below the F line, repeat steps *4 through *8.

      If the coolant level is above the F line, drain coolant until the coolant level reaches the F line.

  15. WARM UP ENGINE


    1. Warm up the engine at less than 1850 rpm for 2 minutes or more after charging the refrigerant.

      Note

      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.

  16. CHECK FOR REFRIGERANT LEAK


    1. After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.

    2. Perform the operation under these conditions:


      • Stop the engine.

      • Secure good ventilation (the halogen leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).

      • Repeat the test 2 or 3 times.

      • 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).

    3. A00JYOBE34
      Text in Illustration
      *1 Halogen Leak Detector
      *a Check for Leakage

      Using a halogen leak detector, check the refrigerant line for leakage.

    4. 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.

    5. Disconnect the connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test.

  17. INSTALL UPPER RADIATOR SUPPORT SEAL


    1. Install the upper radiator support seal with the 13 clips.