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W/Pulley Compressor ASSY: Replacement

WARNING: This page is about a different car, the 2004 Lexus LS 430. However, it is still accessible from the selected car via links, so may be relevant.
  1. DISCONNECT NEGATIVE TERMINAL CABLE FROM BATTER 
  2. EVACUATE REFRIGERANT HFC-134A (R134A) (SEE  REPLACEMENT  ) 
  3. REMOVE AIR CLEANER INLET NO.1 (SEE  REPLACEMENT  ) 
  4. REMOVE FAN AND GENERATOR V BELT (SEE  REPLACEMENT  ) 
  5. REMOVE ENGINE UNDER COVER NO.1 
  6. DISCONNECT COOLER REFRIGERANT DISCHARGE HOSE NO.1 
    1. Remove the nut and disconnect the cooler refrigerant discharge hose No.1.
    2. Remove the O-ring from the cooler refrigerant discharge hose No.1.
      NOTE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
      Fig 1: Locating Nut Cooler Refrigerant Discharge Hose
      G01029481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO.1 
    1. Remove the bolt and disconnect the cooler refrigerant suction hose No.1.
    2. Remove the O-ring from the cooler refrigerant suction hose No.1.
      NOTE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
      Fig 2: Locating Bolt Cooler Refrigerant Suction Hose
      G01029482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE COMPRESSOR MOUNTING BRACKET NO.1 
    1. Remove the bolt, nut and compressor mounting bracket No.1.
      Fig 3: Locating Bolt And Nut Compressor Mounting Bracket
      G01029483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE W/PULLEY COMPRESSOR ASSY 
    1. Disconnect the connector.
    2. Remove the 2 bolts and w/pulley compressor assy.
      Fig 4: Locating Bolts W/Pulley Compressor Assy
      G01029484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. ADJUST COMPRESSOR OIL 
    1. When replacing the compressor and magnetic clutch with a new one, after gradually removing the refrigerant gas from the service valve, drain the following amount of oil from the new compressor and magnetic clutch before installation.

      Standard: 

      (Oil capacity inside the new compressor: 130+15 cc (4.4+0.5 fl.oz)) - (Remaining oil amount in the removed compressor) = (Oil amount to be removed from the new compressor when replacing) 

      NOTE:
      • When checking the compressor oil level, observe the precautions on the air conditioning radiator assy removal/installation.
      • Because compressor oil remains in the pipes of the vehicle, if a new compressor and magnetic clutch is installed without removing some oil inside, the oil amount becomes too much, preventing heat exchange in the refrigerant cycle and causing refrigerant failure.
      • If the remaining oil in the removed compressor and magnetic clutch is too small in volume, check for oil leakage.
      • Be sure to use ND-OIL 8 or equivalent for compressor oil.
  11. TEMPORARILY TIGHTEN W/PULLEY COMPRESSOR ASSY 
    1. Temporarily tighten the w/pulley compressor assy with the 2 bolts.
    2. Connect the connector.
      Fig 5: Locating Bolts W/Pulley Compressor Assy
      G01029485Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL COMPRESSOR MOUNTING BRACKET NO.1 
    1. Install the compressor mounting bracket No.1 with the bolt and nut.

      Torque: 

      Bolt: 49 N.m (500 kgf.cm, 36ft.lbf)

      Nut: 30 N.m (306 kgf.cm, 22 ft.lbf)

      Fig 6: Locating Bolts Compressor Mounting Bracket
      G01029486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. FULLY TIGHTEN W/PULLEY COMPRESSOR ASSY 
    1. Fully tighten the w/pulley compressor assy with the 2 bolts.

      Torque:49 N.m (500 kgf.cm,36 ft.lbf) 

      Fig 7: Locating Bolts Compressor Assy
      G01029487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 
    1. Remove the attached vinyl tape from the hose.
    2. Sufficiently apply compressor oil to the new O-ring and fitting surface of the compressor and magnetic clutch.

      Compressor oil: ND-OIL 8 or equivalent 

    3. Install an O-ring to the cooler refrigerant Suction hose No.1.
    4. Install the cooler refrigerant suction hose No.1 to the compressor and magnetic clutch with the bolt.

      Torque: 9.8 N.m (100 kgf.cm,7 ft.lbf) 

      Fig 8: Locating Bolt Cooler Refrigerant Suction Hose
      G01029488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO.1 
    1. Remove the attached vinyl tape from the hose.
    2. Sufficiently apply compressor oil to the new O-ring and fitting surface of the compressor and magnetic clutch.

      Compressor oil: ND-OIL 8 or equivalent 

    3. Install an O-ring to the cooler refrigerant discharge hose No.1.
    4. Install the cooler refrigerant discharge hose No.1 to the compressor and magnetic clutch with the nut.

      Torque: 9.8 N.m (100 kgf.cm, 7 ft.lbf) 

      Fig 9: Locating Nut Cooler Refrigerant Discharge Hose
      G01029489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL FAN AND GENERATOR V BELT (SEE  REPLACEMENT  ) 
  17. INSTALL AIR CLEANER INLET NO.1 (SEE  REPLACEMENT  ) 
  18. CONNECT NEGATIVE TERMINAL CABLE TO BATTERY 
  19. CHARGE REFRIGERANT (SEE  REPLACEMENT  ) 
  20. WARM UP ENGINE 
  21. INSPECT FOR REFRIGERANT LEAKAGE (SEE  REPLACEMENT  ) 
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