Yaris 2007

Removal & Installation

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  1. Discharge refrigerant from refrigeration system
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove engine under cover RH
  6.  
  7. Remove the alternator and accessory drive belt.
  8.  
  9. Disconnect no. 1 cooler refrigerant suction hose:
    1. Remove the bolt and disconnect the suction hose.
    2.  
    3. Remove the O-ring from the suction hose.
      NOTE
      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

    4.  

  10.  
  11. Disconnect no. 1 cooler refrigerant discharge hose:
    1. Remove the bolt and disconnect the discharge hose.
    2.  
    3. Remove the O-ring from the discharge hose.
      NOTE
      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

    4.  

  12.  
  13. Remove compressor and pulley:
    1. Disconnect the connector.
    2.  
    3. Remove the 4 bolts and compressor.

      Click image to see an enlarged view

      Fig. View of the A/C compressor and components

    4.  

  14.  

To install:

  1. Adjust compressor oil:
    1. When replacing the compressor with a new one, gradually discharge the refrigerant gas from the service valve. Then drain the following amount of oil from the new compressor before installation, so that the amount of oil contained in it is the same as that in the compressor to be replaced.
      NOTE
      New compressors are filled with sufficient oil for the whole cycle. Therefore, it is necessary to drain residual oil from the condenser and cooling unit.

    2.  
    3. Standard: (The amount of oil inside a new compressor: 90 (+15) cc (3.0 (+0.51) fl. oz.)) - (The amount of oil remaining in the removed compressor) = The amount of oil to be removed when replacing the compressor.
      NOTE
      Note the following:



      When checking the compressor oil level, observe the precautions for cooler removal/installation.
       
      If a new compressor is installed without removing the amount of oil remaining in the pipes of the vehicle, the amount of oil becomes too large. This prevents heat exchange in the refrigerant cycle and causes refrigeration failure.
       
      If the amount of oil remaining in the removed compressor is too small, check for oil leakage.
       
      Use ND-OIL8 compressor oil.

      Click image to see an enlarged view

      Fig. Adjusting compressor oil

       

    4.  

  2.  
  3. Provisionally tighten the compressor with the bolt.
  4.  
  5. Tighten the compressor with the 4 bolts.

    Click image to see an enlarged view

    Fig. A/C compressor tightening sequence

  6.  
  7. Connect the connector.
  8.  
  9. Install no. 1 cooler refrigerant discharge hose:
    1. Remove the attached vinyl tape from the hose.
    2.  
    3. Apply sufficient compressor oil (ND-OIL8) to a new O-ring and the fitting surface of the compressor.
    4.  
    5. Compressor oil: ND-OIL8 or the equivalent.
    6.  
    7. Install the O-ring onto the discharge hose.
    8.  
    9. Install the discharge hose onto the compressor with the bolt.
    10.  

  10.  
  11. Install no. 1 cooler refrigerant suction hose:
    1. Remove the attached vinyl tape from the hose.
    2.  
    3. Apply sufficient compressor oil (ND-OIL8) to a new O-ring and the fitting surface of the compressor.
    4.  
    5. Compressor oil: ND-OIL8 or the equivalent.
    6.  
    7. Install the O-ring onto the discharge hose.
    8.  
    9. Install the discharge hose onto the compressor with the bolt.
    10.  

  12.  
  13. To complete installation, reverse the remaining removal procedure.
  14.  
  15. Charge refrigerant.
  16.  
  17. Warm up engine. Warm up the engine at less than 2,000 rpm for 1 minute or more after charging it with refrigerant.
  18.  
  19. Check for refrigerant leak.
  20.  

 
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