COMPRESSOR INSTALLATION


  1. ADJUST COMPRESSOR OIL


    1. A003UMJ

      When replacing the electric inverter compressor with a new one, gradually discharge the refrigerant gas from the service valve, and drain the following amount of oil from the new electric inverter compressor before installation.

      Standard
      (Oil capacity inside the new electric inverter compressor: 130 to 145 cc (4.4 to 4.9 fl. oz.)) - (Remaining oil amount in the removed electric inverter compressor) = (Oil amount to be removed from the new compressor when replacing)

      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, there will be too much oil in the system due to the oil remaining in the pipes of the vehicle. Excessive oil in the system prevents heat exchange in the refrigeration cycle and causes refrigeration failure.

      • If the amount of oil remaining in the old compressor and magnetic clutch is too small, check the A/C system for oil leaks.

      • Be sure to use ND-OIL 11 or equivalent for compressor oil. If any compressor oil other than ND-OIL 11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.

  2. INSTALL ELECTRIC INVERTER COMPRESSOR


    1. Temporarily install the electric inverter compressor with the 3 bolts.

    2. A003TJQE01

      Install the electric inverter compressor with the 3 bolts.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

      Note

      Tighten the bolts in the order shown in the illustration to install the electric inverter compressor.

    3. A003TLSE01

      Engage each clamp.

    4. Connect the connector <A> and lock the green-colored lock as shown in the illustration.

      CAUTION:

      Wear insulated gloves when performing the procedures.

      Text in Illustration
      *1 Green-colored Lock

    5. Connect the connector <B>.

  3. 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 compressor and magnetic clutch.

      Compressor oil
      ND-OIL 11 or equivalent

    3. Install the O-ring onto the suction hose sub-assembly.

      Note


      • Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign objects.

      • Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.

    4. A003RV0

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

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

  4. 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 compressor and magnetic clutch.

      Compressor oil
      ND-OIL 11 or equivalent

    3. Install the O-ring onto the discharge hose sub-assembly.

      Note


      • Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign objects.

      • Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.

    4. A003S0B

      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 }

  5. CONNECT NO. 2 RADIATOR HOSE


    1. A003UW3

      Connect the No. 2 radiator hose to the radiator assembly with the clamp.

  6. INSTALL INLET AIR CLEANER ASSEMBLY


    1. Install the inlet air cleaner assembly with the 3 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Connect the No. 4 water by-pass hose to the inlet air cleaner assembly with the clamp.

  7. INSTALL SERVICE PLUG GRIP

    CAUTION:

    Wear insulating gloves.

    Note

    Before connecting the service plug, check that no parts and tools remain and that the high voltage terminals and connectors are connected securely.


    1. Wear insulated gloves and install the service plug grip in the order shown in the illustration.

      A003UES

    2. Rotate the handle of the service plug grip 90° toward the battery and slide it in the direction shown by the arrow until a click sound is heard.

  8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  9. INSTALL BATTERY BOX COVER


    1. Engage the 3 guides to install the battery box cover.

  10. INSTALL REAR DECK FLOOR BOX


    1. Install the rear deck floor box.

  11. INSTALL REAR FLOOR MAT


    1. Install the rear floor mat.

  12. CHARGE WITH REFRIGERANT


    1. Perform vacuum purging using a vacuum pump.

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

      Standard
      440 to 500 g (15.5 to 17.6 oz.)
      SST
      09985-20010   ( 09985-02010, 09985-02050, 09985-02060, 09985-02070, 09985-02080, 09985-02090, 09985-02110, 09985-02130, 09985-02140, 09985-02150 )

      Note


      • Do not turn the A/C on before charging with refrigerant. Doing so will cause the compressor to work without refrigerant, resulting in overheating of the cooler compressor.

      • 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.

      • Avoid using a gauge manifold set that had been used on vehicles with conventional compressor oil (ND-OIL 8 or equivalent) as much as possible. This will cause compressor oil remaining in the manifold to enter the vehicle, resulting in insulation performance deterioration. A gauge manifold set that had been used 3 times or less can be reused if an appropriate one is not available.

      Tech Tips

      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.

  13. ADD COOLANT (for Engine)


    1. Tighten the radiator drain cock plug.

    2. Connect the hose to the air release valve. (w/ Air Release Valve)

    3. Loosen the air release valve. (w/ Air Release Valve)

    4. Add TOYOTA Super Long Life Coolant (SLLC) to the reservoir tank filler opening until coolant overflows from the air release valve. Then tighten the air release valve. (w/ Air Release Valve)

    5. Disconnect the hose from the air release valve. (w/ Air Release Valve)

    6. A003TGQE01
      Text in Illustration
      *1 B Line

      Add TOYOTA Super Long Life Coolant (SLLC) to the B line on the reservoir tank.

      Standard Capacity
      Item Capacity
      Engine coolant

      w/ Exhaust Heat Recirculation System:

      7.2 liters (7.6 US qts, 6.3 lmp. qts)

      w/o Exhaust Heat Recirculation System:

      6.5 liters (6.8 US qts, 5.7 lmp. qts)

      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 is a combination of low phosphates and organic acids).

      Note

      Never use water as a substitute for engine coolant.

    7. Squeeze 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.

    8. Put the engine in inspection mode Click here.

    9. Install the reservoir tank cap.

    10. Bleed air from the cooling system.

      Note


      • Before starting the engine, turn the A/C switch off.

      • Adjust the heater control to the maximum hot setting.

      • Adjust the blower speed to the low setting.


      1. Warm up the engine until the thermostat opens. While the thermostat is open, allow the coolant to circulate for several minutes.

        Tech Tips

        The thermostat opening timing can be confirmed by squeezing the inlet radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the hose.

        CAUTION:

        When squeezing the radiator hose:

        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

      2. Squeeze the inlet and outlet radiator hoses several times by hand to bleed air from the system.

        CAUTION:

        When squeezing the radiator hose:

        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

    11. A003TGQE02
      Text in Illustration
      *1 Full Line
      *2 Low Line

      After the engine has cooled down, check that the coolant level is between full and low lines.

      If the coolant level is low, add coolant to the full line on the reservoir tank.

  14. WARM UP COMPRESSOR


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

      Note

      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.

  15. INSPECT FOR REFRIGERANT LEAK


    1. After recharging with refrigerant, inspect for refrigerant leaks using a halogen leak detector.

    2. Carry out the test under the following conditions:


      • Turn the power switch off.

      • Secure good ventilation (the halogen leak detector may react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas).

      • Repeat the test 2 or 3 times.

      • Make sure that there is some refrigerant remaining in the refrigeration system.

        When the compressor is off: approx. 392 to 588 kPa (3.9 to 5.9 kgf/cm2, 57 to 85 psi)

    3. A003T91E31
      Text in Illustration
      *1 Inspect for Leak
      *2 Halogen Leak Detector

      Using a halogen leak detector, inspect for refrigerant leaks from the refrigerant lines.

    4. A003U02E08
      Text in Illustration
      *1 Halogen Leak Detector
      *2 Drain Hose

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

      Tech Tips


      • After the blower motor has stopped, let the cooling unit stand for more than 15 minutes.

      • Bring the halogen leak detector sensor under the drain hose.

      • When bringing the halogen leak detector close to the drain hose, make sure that the halogen 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.

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

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

  16. INSPECT FOR COOLANT LEAK (for Engine)

    CAUTION:

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

    Note

    Before performing each inspection, turn the A/C switch off.


    1. Remove the reservoir tank cap.

    2. A003T8A

      Fill the radiator and reservoir with coolant, and then attach a radiator cap tester.

    3. Put the engine in inspection mode Click here.

    4. Warm up the engine.

    5. Using a radiator cap tester, increase the pressure inside the radiator to 108 kPa (1.1 kgf/cm2, 16 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator, front exhaust pipe assembly and the heater hose around and engine water pump assembly for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

    6. Remove the radiator cap tester.

    7. Install the reservoir tank cap.

  17. INSTALL NO. 1 ENGINE UNDER COVER