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W/Pulley Compressor ASSY: Replacement

WARNING: This page is about a different car, the 2004 Scion xB. However, it is still accessible from the selected car via links, so may be relevant.
  1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See  REPLACEMENT   ) 

    SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)

  2. REMOVE ENGINE UNDER COVER 
  3. REMOVE FAN AND GENERATOR V BELT (See  DRIVE BELT  ) 
  4. DISCONNECT COOLER REFRIGERANT DISCHARGE HOSE NO. 1 
    1. Remove the bolt and disconnect the cooler refrigerant discharge hose No. 1 from the w/pulley compressor assy.
    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: Disconnecting Cooler Refrigerant Discharge Hose No. 1 From W/Pulley Compressor Assembly
    G00759522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. DISCONNECT SUCTION HOSE SUB-ASSY 
    1. Remove the bolt and disconnect the suction hose SUB-ASSY from the w/pulley compressor assy.
    2. Remove the O-ring from the suction hose SUB-ASSY.
    NOTE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
    Fig 2: Disconnecting Suction Hose Sub-Assembly From W/Pulley Compressor Assembly
    G00759523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE W/PULLEY COMPRESSOR ASSY 
    1. Disconnect the connector.
    2. Remove the 4 bolts and the w/pulley compressor assy.
      Fig 3: Removing W/Pulley Compressor Assembly
      G00759524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSPECT COMPRESSOR OIL 
    1. When replacing the w/pulley compressor assy with a new one, after gradually removing the refrigerant gas from the service valve, drain the following amount of oil from the new w/pulley compressor assy before installation.

      Standard: 

      (Oil capacity inside new compressor : 60 + 15 cc (3.0 + 0.5 fl. oz.)) - (Remaining oil amount in the removed compressor) = (Oil amount to be removed when replacing) 

    NOTE:
    • When checking the compressor oil level, observe the precautions for cooler removal / installation.
    • Because compressor oil remains in the pipes of the vehicle, if a new compressor is installed without removing some of the remaining oil, 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 is too small in volume, check for oil leakage.
    • Be sure to use ND-OIL 8 for compressor oil.
  8. INSTALL W/PULLEY COMPRESSOR ASSY 
    1. Install the w/pulley compressor assy with the 4 bolts.

      Torque: 25 N.m (255kgf.cm, 221in. lbf) 

      NOTE: Tighten the bolts in the order as shown in the illustration to install the w/pulley compressor assy.
    2. Connect the connector.
      Fig 4: Installing W/Pulley Compressor Assembly
      G00759525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL SUCTION HOSE SUB-ASSY 
    1. Remove the attached vinyl tape from the hose.
    2. Apply a sufficient amount of compressor oil to a new O-ring and fit surface of the w/pulley compressor assy.

      Compressor oil: ND-OIL 8 or equivalent 

    3. Install the new O-ring on the suction hose SUB-ASSY.
    4. Install the suction hose SUB-ASSY on the w/pulley compressor assy with the bolt.
      Fig 5: Installing Suction Hose Sub-Assembly
      G00759526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO. 1 
    1. Remove the attached vinyl tape from the hose.
    2. Apply a sufficient amount of compressor oil to a new O-ring and fit surface of the compressor and magnetic clutch.

      Compressor oil: ND-OIL 8 or equivalent 

    3. Install the O-ring to the cooler refrigerant discharge hose No. 1, then install it to the w/pulley compressor assy with the bolt.
    4. Install the cooler refrigerant discharge hose No. 1 to the w/pulley compressor assy with the bolt.

      Torque: 9.8 N.m (100 kgf.cm, 87 in. lbf) 

      Fig 6: Installing Cooler Refrigerant Discharge Hose No. 1
      G00759527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL FAN AND GENERATOR V BELT (See  DRIVE BELT  ) 
  12. ADJUST FAN AND GENERATOR V BELT (See  DRIVE BELT  ) 
  13. CHARGE REFRIGERANT (See  REPLACEMENT   ) 

    SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)

    Specified amount: 380 +/- 30 g (13.9 +/- 1.1 oz.) 

  14. WARM UP ENGINE (See  REPLACEMENT   ) 
  15. INSPECT LEAKAGE OF REFRIGERANT (See  REPLACEMENT   ) 
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