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Cooler Compressor ASSY: Replacement

WARNING: This page is about a different car, the 2004 Lexus ES 330, 2003 Lexus ES 300, and 2002 Lexus ES 300. However, it is still accessible from the selected car via links, so may be relevant.

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See COMPONENTS 

  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 V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See  REPLACEMENT   ) 
  3. REMOVE GENERATOR ASSY (See  GENERATOR  ,  GENERATOR  ) 
  4. DISCONNECT COOLER REFRIGERANT DISCHARGE HOSE NO.1 
    1. Remove the nut and disconnect the cooler refrigerant discharge hose No. 1.
      Fig 1: Disconnecting Cooler Refrigerant Discharge Hose No.1
      G00902887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
  5. DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO.1 
    1. Remove the nut and disconnect the cooler refrigerant suction hose No. 1.
      Fig 2: Disconnecting Cooler Refrigerant Suction Hose No. 1
      G00902888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
  6. REMOVE COMPRESSOR AND MAGNETIC CLUTCH 
    1. Disconnect the connector and clamp.
    2. Remove the 2 bolts, nut and cooler compressor bracket.
      Fig 3: Removing Cooler Compressor Bracket
      G00902889Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 3 bolts and compressor and magnetic clutch.
      Fig 4: Removing Compressor & Magnetic Clutch
      G00902890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE COOLER COMPRESSOR BRACKET 
    1. Remove the screw, earth wire and cooler compressor bracket.
      Fig 5: Removing Cooler Compressor Bracket
      G00902891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE MAGNET CLUTCH ASSY 
    1. Remove the bolt and bracket.
      Fig 6: Removing Magnet Clutch Bolt & Bracket
      G00902892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place the compressor and magnetic clutch in vise.
    3. Using a vise pliers, hold the magnet clutch hub.
      Fig 7: Holding Magnet Clutch Hub Using Vise Pliers
      G00902893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt, magnet clutch hub and magnet clutch washer.
    5. Using a snap ring expander, remove the snap ring and magnet clutch rotor.
      Fig 8: Removing Snap Ring & Magnet Clutch Rotor
      G00902894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disconnect the connector.
    7. Using a snap ring expander, remove the snap ring and magnet clutch starter.
      Fig 9: Removing Snap Ring & Magnet Clutch Starter
      G00902895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE COOLER COMPRESSOR ASSY 
  10. INSTALL MAGNET CLUTCH ASSY 
    1. Matching the parts shown in Fig 10 , install the magnet clutch starter.
      Fig 10: Matching Magnet Clutch Parts
      G00902896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a snap ring expander, install a new snap ring with the chamfered side facing up.
      Fig 11: Installing New Snap Ring
      G00902897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the connector.
    4. Using a snap ring expander, install the magnet clutch rotor and a new snap ring with the chamfered side facing up.
      Fig 12: Installing Magnet Clutch Rotor & Snap Ring
      G00902898Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the magnet clutch washer and magnet clutch hub.
      NOTE: Do not change the combination of the magnet clutch washers used before disassembly.
    6. Using a vise pliers, hold the magnet clutch hub and install the bolt.

      Torque: 18 N.m (184 kgf.cm, 13 ft.lbf) 

      Fig 13: Holding Magnet Clutch Hub
      G00902899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSPECT MAGNETIC CLUTCH CLEARANCE 
    1. Set the dial indicator to the magnet clutch hub.
      Fig 14: Setting Dial Indicator To Magnet Clutch Hub
      G00902900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the battery positive lead to the terminal 3 of magnet clutch connector and the negative lead to the earth wire. Turn on and off the magnet clutch and measure the clearance.

      Standard clearance: 0.35 - 0.60 mm (0.014 - 0.024 in.) 

      If the measured value is out of the standard range, remove the magnet clutch hub and adjust it with magnet clutch washers.

      NOTE: Adjustment shall be performed with 3 or less magnet clutch washers.
    3. Remove the compressor and magnetic clutch from the vise.
    4. Install the bolt and bracket.
      Fig 15: Installing Magnetic Clutch
      G00902901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL COOLER COMPRESSOR BRACKET 
    1. Install the earth wire and cooler compressor bracket with the screw.
      Fig 16: Installing Cooler Compressor Bracket
      G00902902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSPECT COMPRESSOR OIL 
    1. When replacing the compressor and magnetic clutch with 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 new compressor and magnetic clutch: 120 + 15 cc (4.1 + 0.51 fl.oz.)) - (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed when replacing) 
      NOTE:
      • When checking the compressor oil level, observe the precautions on the cooler 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-OIL8 for compressor oil.
  14. TEMPORARY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH 
    1. Temporarily tighten the compressor and magnetic clutch with the 3 bolts.
      Fig 17: Temporarily Tightenening Compressor & Magnetic Clutch
      G00902903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. FULLY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH 
    1. Tighten the compressor and magnetic clutch with the bolt (A) and bolt (B).

      Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) 

      Fig 18: Tightening Compressor & Magnetic Clutch
      G00902904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the cooler compressor bracket with the 2 bolts and nut.

      Torque: 

      • 25 N.m (250 kgf.cm, 18 ft.lbf) (Bolt (C)) 
      • 25 N.m (250 kgf.cm, 18 ft.lbf) (Nut (D)) 
      • 18 N.m (184 kgf.cm, 13 ft.lbf) (Bolt (E)) 
      Fig 19: Installing Cooler Compressor Bracket
      G00902905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Tighten the compressor and magnetic clutch with the bolt (F).

      Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) 

      Fig 20: Tightening Compressor & Magnetic Clutch
      G00902906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the connector.
  16. 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 fit surface of the compressor and magnetic clutch.

      Compressor oil: ND-OIL 8 or equivalent 

    3. Install a 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 nut.

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

      Fig 21: Installing Cooler Refrigerant Suction Hose No. 1 & Magnetic Clutch
      G00902907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. 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 fit surface of the compressor and magnetic clutch.

      Compressor oil: ND-OIL 8 or equivalent 

    3. Install a 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, 87 in.lbf) 

      Fig 22: Installing Cooler Refrigerant Discharge Hose No.1 & Magnetic Clutch
      G00902908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL GENERATOR ASSY (See  GENERATOR  ,  GENERATOR  ) 
  19. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See  REPLACEMENT   ) 
  20. 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: 550 +/- 50 g (19.37 +/- 1.76 oz.) 

  21. WARM UP ENGINE 
  22. INSPECT LEAKAGE OF REFRIGERANT (See  REPLACEMENT   ) 
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