Scion 2005-06

Removal & Installation

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1.5L Engines




CAUTION
Refer to the applicable precautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death.

  1. Discharge refrigerant from refrigeration system, as outlined in this section.
  2.  
  3. Remove the right side engine under cover.
  4.  
  5. Remove the fan-generator, as outlined in the Engine Mechanical section/
  6.  
  7. Disconnect cooler refrigerant discharge hose no.1:
    1. Remove the bolt and disconnect the cooler refrigerant discharge hose no.1 from the compressor.
    2.  
    3. Remove the o-ring from the cooler refrigerant discharge hose no.1.
      NOTE
      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

    4.  

  8.  
  9. Disconnect the suction hose, as follows:
    1. Remove the bolt and disconnect the suction hose subassembly From the compressor.
    2.  
    3. Remove the o-ring from the suction hose sub- assembly.
      NOTE
      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

    4.  

  10.  
  11. Remove the 4 bolts and the compressor.
  12.  

To install:

  1. Check and adjust the compressor oil, as follows:
    1. When replacing the compressor with a new one, after gradually removing the refrigerant gas from the service valve, drain the following amount of oil from the new compressor before installation.
      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 or equivalent for compressor oil.



      Standard: (oil capacity inside new compressor: 60 + 15 cc (2.0 + 0.5 fl. Oz.)) - (remaining oil amount in The removed compressor) = (oil amount to be removed when replacing)
       

    2.  

  2.  
  3. Install the compressor assembly with the 4 bolts. Install and tighten the bolts to 18 ft. lbs. (25 Nm), in the order shown in the illustration.

    Click image to see an enlarged view

    Fig. Install and tighten the compressor mounting bolts in the correct order

  4.  
  5. Attach the electrical the connector.
  6.  
  7. Install suction hose, as follows:
    1. Remove the attached vinyl tape from the hose.
    2.  
    3. Apply a sufficient amount of compressor oil (ND-Oil 8) to a new O-ring and fit surface of the compressor.
    4.  
    5. Install the O-ring on the suction hose.
    6.  
    7. Install the suction hose on the compressor with the bolt and tighten to 87 inch lbs. (9.8 Nm).
    8.  

  8.  
  9. Install cooler refrigerant discharge hose no.1:
    1. Remove the attached vinyl tape from the hose.
    2.  
    3. Apply a sufficient amount of compressor oil to a new O-ring and contact surface of the compressor.
    4.  
    5. Install the O-ring to the cooler refrigerant discharge hose no.1.
    6.  
    7. Install the cooler refrigerant discharge hose no.1 to the compressor assembly with the bolt and tighten to 87 inch lbs. (9.8 Nm).
    8.  

  10.  
  11. Install and adjust the fan-alternator belt, as outlined in the Engine Mechanical Section.
  12.  
  13. Charge the refrigerant, as outlined in this section.
  14.  
  15. Warm up the engine and check for any refrigerant leakage.
  16.  

2.4L Engines




CAUTION
Refer to the applicable precautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death.

  1. Discharge refrigerant from refrigeration system, as outlined in this section.
  2.  
  3. Disconnect cooler refrigerant suction hose no.1:
    1. Remove the bolt and disconnect the cooler refrigerant suction hose no.1 from the compressor.
    2.  
    3. Remove the o-ring from the cooler refrigerant suction hose no.1.
      NOTE
      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering the A/C system.

    4.  

  4.  
  5. Disconnect cooler refrigerant discharge hose no.1, as follows:
    1. Remove the bolt and disconnect the cooler refrigerant discharge hose no.1 from the compressor.
    2.  
    3. Remove the O-ring from the cooler refrigerant discharge hose no.1.
      NOTE
      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering the A/C system.

    4.  

  6.  
  7. Remove the right side engine under cover.
  8.  
  9. Remove the fan and generator belt, as outlined in the Engine Mechanical Section.
  10.  
  11. Detach the compressor connector, unfasten the 4 bolts, the remove the compressor from the vehicle.

    Click image to see an enlarged view

    Fig. Exploded view of the A/C compressor mounting

  12.  

To install:

  1. Adjust compressor oil, as follows:
    1. When replacing the compressor with a new one, after gradually removing the refrigerant gas from the service valve, drain the following amount of oil from the new compressor before installation.
      NOTE
      When checking the compressor oil level, observe the precautions on the cooler removal/installation. Since compressor oil remains in the pipes of the vehicle, if a new compressor is installed without removing some oil inside, the oil amount becomes excessive, preventing heat exchange in the refrigerant cycle and causing refrigerant failure. If the remaining oil in the removed compressor is too small of an amount, check for oil leakage. Always use ND-Oil 8 for compressor oil.



      Standard: (oil capacity inside new compressor: 140 + 15 cc (4.7 + 0.5 fl. Oz.) ) - (remaining oil amount in the removed compressor) = (oil amount to be removed when replacing)
       

    2.  

  2.  
  3. Install the compressor and secure with the 4 bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  4.  
  5. Attach the compressor electrical connector.
  6.  
  7. Install cooler refrigerant discharge hose no.1:
    1. Remove the tape from the hose.
    2.  
    3. Apply compressor oil to a new o-ring and the mating surface of the compressor.
    4.  
    5. Install the o-ring on the cooler refrigerant discharge hose no.1.
    6.  
    7. Install the cooler refrigerant discharge hose no.1 on the compressor with the bolt and tighten to 87 inch lbs. (9.8 Nm).
    8.  

  8.  
  9. Install cooler refrigerant suction hose no.1:
    1. Remove the vinyl tape from the hose.
    2.  
    3. Apply compressor oil to a new O-ring and the mating surface of the compressor.
    4.  
    5. Install the o-ring on the cooler refrigerant suction hose no.1.
    6.  
    7. Install the cooler refrigerant suction hose no.1 on the compressor with the bolt and tighten to 87 inch lbs. (9.8 Nm).
    8.  

  10.  
  11. Install and adjust the fan-alternator belt, as outlined in the Engine Mechanical Section.
  12.  
  13. Charge the refrigerant, as outlined in this section.
  14.  
  15. Warm up the engine and check for any refrigerant leakage.
  16.  

 
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