2GR-FE COMPRESSOR INSTALLATION


  1. TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH


    1. for Standard Bolt:


      1. A019MM7E01
        Text in Illustration
        *1 Bracket

        Temporarily install the compressor and magnetic clutch and the bracket with the 4 bolts.

    2. for Stud Bolt:


      1. A019M5TE01
        Text in Illustration
        *1 Bracket
        *2 Stud bolt
        *2 Bolt

        Temporarily install the compressor and magnetic clutch and the bracket with the 2 stud bolts and 2 bolts.

  2. INSTALL COMPRESSOR AND MAGNETIC CLUTCH


    1. for Standard Bolt:


      1. A019N95E01

        Install the compressor and magnetic clutch with the 4 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 compressor and magnetic clutch.

    2. for Stud Bolt:


      1. A019M2Q

        Using a "TORX" socket wrench (E8), install the 2 stud bolts.

        Torque:
        25 N*m  { 250 kgf*cm, 18 ft.*lbf }
      2. A019M2LE01

        Install the compressor assembly with pulley with the 2 bolts and 2 nuts.

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

        Note

        Tighten the bolts and nuts in the order shown in the illustration to install the compressor and magnetic clutch.

    3. Engage each clamp.

    4. Connect each connector.

  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 8 or equivalent

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

      CAUTION:

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

    4. A019OK0

      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 8 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.

    4. A019PDD

      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. INSTALL RADIATOR ASSEMBLY AND FAN ASSEMBLY WITH MOTOR

    Tech Tips

    Refer to the procedure for Install No. 2 Radiator Assembly Click here.

  6. INSTALL COOLER CONDENSER ASSEMBLY


    1. A019OFS

      Install the cooler condenser assembly as shown in the illustration.

      Note


      • Due to the potential of damaging the brackets, do not allow the brackets to touch the vehicle body etc. while installing the condenser.

      • Do not allow the condenser to contact the vehicle body or radiator while installing the condenser.

      Tech Tips

      If the condenser is replaced with a new one, add compressor oil to the new condenser.

      Capacity
      40 cc (1.35 fl.oz.)
      Compressor oil
      ND-OIL 8 or equivalent
    2. A019P2X

      Install the 2 cooler brackets with the 2 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  7. INSTALL UPPER RADIATOR SUPPORT


    1. A019ODYE01
      Text in Illustration
      *1 Bolt

      Install the upper radiator support with the 5 bolts and connect the 3 clamps of the hood lock control cable to the upper radiator support.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  8. CONNECT OUTLET OIL COOLER HOSE


    1. A019O3J

      Connect the outlet oil cooler hose to the radiator.

  9. CONNECT INLET OIL COOLER HOSE


    1. A019JZN

      Connect the clamp and inlet oil cooler hose to the radiator.

  10. CONNECT NO. 2 RADIATOR HOSE


    1. A019K90

      Connect the No. 2 radiator hose to the radiator.

  11. CONNECT NO. 1 RADIATOR HOSE


    1. A019JYY

      Connect the No. 1 radiator hose to the radiator.

  12. INSTALL RADIATOR RESERVE TANK ASSEMBLY


    1. A019OG6

      Connect the radiator reserve tank hose to the radiator.

    2. A019N1D

      Install the radiator reserve tank with the bolt and connect the 2 clamps to the radiator.

      Torque:
      5.3 N*m  { 54 kgf*cm, 47 in.*lbf }

  13. CONNECT DISCHARGE TUBE SUB-ASSEMBLY


    1. Remove the attached vinyl tape from the tube and the connecting part of the cooler condenser assembly.

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

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring on the discharge tube sub-assembly.

      Note

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

    4. A019OAT

      Install the discharge tube sub-assembly on the cooler condenser assembly with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  14. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY


    1. Remove the attached vinyl tape from the pipe and the connecting part of the cooler condenser assembly.

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

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring on the air conditioning tube and accessory assembly.

      Note

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

    4. A019OYB

      Install the air conditioning tube and accessory assembly on the cooler condenser assembly with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  15. INSTALL BATTERY


    1. Install the battery and battery tray.

    2. A019LTJ

      Install the battery clamp with the bolt and nut.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

    3. Connect the positive (+) cable to the positive (+) battery terminal.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

  16. INSTALL NO. 1 AIR CLEANER INLET


    1. A019ND6

      Install the No. 1 air cleaner inlet with the bolt.

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

    2. Connect the vacuum hose clamp to the No. 1 air cleaner inlet.

  17. INSTALL NO. 2 AIR CLEANER INLET


    1. A019O60

      Install the No. 2 air cleaner inlet with the 2 bolts.

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

    2. Connect the 2 vacuum hose clamps to the No. 2 air cleaner inlet.

  18. INSTALL HOOD LOCK SUPPORT SUB-ASSEMBLY


    1. A019KL0

      Install the hood lock support sub-assembly with the 2 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 8 ft.*lbf }

    2. Engage each clamp.

  19. INSTALL SMOG VENTILATION SENSOR (w/ Smog Ventilation Sensor)


    1. A019LDV

      Engage the guide.

    2. Install the smog ventilation sensor with the bolt.

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

    3. Connect the connector.

  20. INSTALL HIGH PITCHED HORN ASSEMBLY


    1. A019LXM

      Install the high pitched horn assembly with the bolt.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

    2. Connect the connector.

  21. INSTALL HOOD LOCK ASSEMBLY (for LHD)


    1. A019JXY

      Apply MP grease to the sliding areas of the lock.

    2. A019K84

      Connect the hood lock control cable assembly.

    3. Connect the connector.

    4. A019OVS

      Install the hood lock assembly with the 2 bolts and hood lock nut.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. A019K2X

      Install a new hood lock nut cap.

  22. INSTALL HOOD LOCK ASSEMBLY (for RHD)


    1. A019NVN

      Apply MP grease to the sliding areas of the lock.

    2. A019JRS

      Connect the hood lock control cable assembly.

    3. Connect the connector.

    4. A019O9S

      Install the hood lock assembly with the 2 bolts and hood lock nut.

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

  23. INSTALL HOOD LOCK CONTROL CABLE COVER (for LHD)


    1. A019P5I

      Engage the clamp.

    2. Install the hood lock control cable cover with the 3 screws.

  24. INSTALL HOOD LOCK CONTROL CABLE COVER (for RHD)


    1. A019PAW

      Engage the clamp.

    2. Install the hood lock control cable cover with the 3 screws.

  25. INSTALL LOW PITCHED HORN ASSEMBLY


    1. A019OJ0

      Install the low pitched horn assembly with the bolt.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

    2. Connect the connector.

  26. INSTALL MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System)


    1. A019LF9E01

      Tighten the 3 bolts on the millimeter wave radar sensor assembly.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

      Tech Tips

      Tighten the bolts in the order indicated in the illustration.

    2. Connect the connector.

  27. INSTALL FRONT BUMPER ASSEMBLY

    for Standard: Click here

    for Sport Package: Click here

  28. INSTALL V-RIBBED BELT


    1. A019OSRE02
      Text in Illustration
      *1 Water Pump
      *2 Idler
      *3 Generator
      *4 Crankshaft
      *5 V-ribbed belt Tensioner
      *6 A/C Compressor

      Install the V-ribbed belt.

    2. A019NA3

      Turn the V-ribbed belt tensioner counterclockwise and remove a 5 mm bi-hexagon wrench.

    3. After installing the V-ribbed belt, check that it fits properly in the ribbed grooves. Confirm that the belt has not slipped out of the grooves on the bottom of the crank pulley by hand.

  29. INSTALL FRONT FENDER APRON SEAL RH


    1. A019O37

      Install the front fender apron seal RH with the 2 bolts and clip.

  30. INSTALL FRONT FENDER LINER RH


    1. A019NHQE01
      Text in Illustration
      *1 Grommet

      Install 3 new grommets and 6 screws.

    2. Install the 7 clips.

    3. A019MAO

      Using a 4 mm hexagon wrench, install the front fender liner RH with the 4 hexagon screws.

    4. A019PEFE01
      Text in Illustration
      *1 Correct
      *2 Incorrect

      Install the 2 pin hold clips.

      Note

      Insert the pin hold with the slot aligned vertically. Do not rotate the clip after inserting it. After installation, confirm that the slot is vertical.

  31. INSTALL FRONT WHEEL RH

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }

  32. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  33. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. Tighten the 2 cylinder block drain cock plugs.

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

    3. Remove the radiator cap.

    4. Loosen the air drain cock plug on the water inlet housing.

    5. Add TOYOTA Super Long Life Coolant (SLLC) to the radiator inlet opening until coolant overflows from the air drain cock hole. Then tighten the air drain cock plug to the water inlet housing.

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

    6. Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

      Standard capacity
      9.5 liters (10.0 US qts, 8.3 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).

      • Contact your TOYOTA dealer for further details.

      Note

      Never use water as a substitute for engine coolant.

    7. Tighten the air drain plug.

    8. A019MVWE01
      Text in Illustration
      *1 FULL Line

      Slowly pour coolant into the radiator reservoir tank until it reaches the FULL line.

    9. Install the radiator cap.

    10. Squeeze the No. 1 and No. 2 radiator hoses several times by hand, and then check the level of the coolant.

      If the coolant level is low, add coolant.

    11. Bleed air from the cooling system.


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

        Tech Tips

        The thermostat open timing can be confirmed by squeezing the No. 2 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

      2. Maintain the engine speed at 2500 to 3000 rpm.

      3. Squeeze the inlet and No. 1 and No. 2 radiator hoses several times by hand to bleed air.

        CAUTION:

        When squeezing the radiator hoses:


        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the cooling fans.

        Note


        • Make sure that the radiator reservoir still has some coolant in it.

        • If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool.

        • If there is not enough coolant, the engine may overheat or be seriously damaged.

        • If the radiator reservoir does not have enough coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the reservoir is filled to the FULL line.

    12. Stop the engine and wait until the engine coolant cools down.

    13. Add engine coolant to the FULL line on the radiator reservoir.

  34. CHARGE WITH REFRIGERANT


    1. Perform vacuum purging using a vacuum pump.

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

      A019MUNE05
      Standard (for Suction Pipe Separate Type)
      450 to 550 g (15.9 to 19.4 oz.)
      Standard (except Suction Pipe Separate Type)
      500 to 600 g (17.6 to 21.2 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 switch on before charging with refrigerant. Doing so will cause the compressor to work without refrigerant, resulting in overheating of the compressor.

      • Approximately 100 g (3.5 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, not with the sight glass.

      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.

  35. WARM UP ENGINE


    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 switch on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

  36. 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 engine 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 (4 to 6 kgf/cm2, 57 to 85 psi)

    3. A019KMKE31
      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. A019MG9E08
      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.

  37. INSPECT FOR COOLANT LEAK

    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.

    Note

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


    1. Remove the radiator cap.

    2. A019MDJ

      Fill the radiator with coolant and attach a radiator cap tester.

    3. Warm up the engine.

    4. Using the radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm2, 17 psi), and check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

    5. Remove the radiator cap tester.

    6. Install the radiator cap.

  38. INSPECT AUTOMATIC TRANSAXLE FLUID

    for U660F: Click here

  39. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. A019LVN

      Fit the 4 retainers and install the V-bank cover sub-assembly.

  40. INSTALL NO. 1 ENGINE UNDER COVER

  41. INSPECT HOOD SUB-ASSEMBLY


    1. Inspect the hood sub-assembly Click here.

  42. ADJUST HOOD SUB-ASSEMBLY


    1. Adjust the hood sub-assembly Click here.