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Cooler Compressor ASSY: Replacement

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COMPONENTS: 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. DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO. 1 
    1. Remove the bolt and disconnect the cooler refrigerant suction hose No. 1 from the compressor and magnetic clutch.
    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 1: Disconnecting Cooler Refrigerant Suction Hose
    G02900247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. DISCONNECT DISCHARGE HOSE SUB-ASSY 
    1. Remove the bolt and disconnect the discharge hose sub-assy from the compressor and magnetic clutch.
    2. Remove the O-ring from the discharge 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 Discharge Hose Sub-Assy
    G02900248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE ENGINE UNDER COVER RH 
  5. REMOVE FAN AND GENERATOR V BELT (See  REPLACEMENT  ) 
  6. REMOVE COMPRESSOR AND MAGNETIC CLUTCH 
    1. Disconnect the connector.
    2. Remove the 3 bolts and compressor and magnetic clutch.
    Fig 3: Removing Compressor And Magnetic Clutch
    G02900249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE MAGNET CLUTCH ASSY 
    1. Place the compressor and magnetic clutch in vise.
    2. Using a vise pliers, hold the magnet clutch hub.
    3. Remove the bolt, magnet clutch hub and magnet clutch washer.
      Fig 4: Removing Bolt, Magnet Clutch Hub And Magnet Clutch Washer
      G02900250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a snap ring expander, remove the snap ring and magnet clutch rotor.
    5. Remove the screw, disconnect the connector.
      Fig 5: Removing Snap Ring And Magnet Clutch Rotor
      G02900251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a snap ring expander, remove the snap ring and magnet clutch starter.
    Fig 6: Removing Snap Ring And Magnet Clutch Starter
    G02900252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE COOLER COMPRESSOR ASSY 
  9. INSTALL MAGNET CLUTCH ASSY 
    1. Matching the parts shown in the illustration, install the magnet clutch starter.
      Fig 7: Installing Magnet Clutch Assy
      G02900253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a snap ring expander, install a new snap ring with the chamfered side facing up.
    3. Install the screw, connect the connector.
      Fig 8: Installing Snap Ring With Chamfered Side Facing Up
      G02900254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a snap ring expander, install the magnet clutch rotor and a new snap ring with the chamfered side facing up.
    5. Install the magnet clutch washer and magnet clutch hub.
      NOTE: Do not change the combination of the magnet clutch washers used before disassembly.
      Fig 9: Installing Magnet Clutch Rotor And New Snap Ring With Chamfered Side Facing Up
      G02900255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a vise pliers, hold the magnet clutch hub and install the bolt.

      Torque: 18 N.m (183 kgf.cm, 13 ft.lbf) 

    Fig 10: Holding Magnet Clutch Hub
    G02900256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSPECT MAGNETIC CLUTCH CLEARANCE 
    1. Set the dial indicator to the magnet clutch hub.
    2. Connect the battery positive lead to the terminal 1 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 (0.013 - 0.023 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.
    Fig 11: Inspecting Magnetic Clutch Clearance
    G02900257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. 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 (4.0 + 0.5 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.
  12. INSTALL COMPRESSOR AND MAGNETIC CLUTCH 
    1. Install the compressor and magnetic clutch with the 3 bolts.

      Toque: 29 N.m (295 kgf.cm, 21 ft.lbf) 

      NOTE: Tighten the bolts in following order shown in the illustration to install the compressor and magnetic clutch.
    2. Connect the connector.
    Fig 12: Installing Compressor And Magnetic Clutch
    G02900258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL DISCHARGE HOSE SUB-ASSY 
    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-OIL8 or equivalent 

    3. Install a O-ring to the discharge hose sub-assy.
    4. Install the discharge hose sub-assy to the compressor and magnetic clutch with the bolt.

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

    Fig 13: Installing Discharge Hose Sub-Assy To Compressor And Magnetic Clutch With Bolt
    G02900259Courtesy 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 fit surface of the compressor and magnetic clutch.

      Compressor oil: ND-OIL8 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 bolt.

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

    Fig 14: Installing Cooler Refrigerant Suction Hose
    G02900260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. CHARGE REFRIGERANT (See  REPLACEMENT  ) 

    SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080), 07117-48130, 07117-48140

    Specified amount: 490 +/- 30 g (17.28 +/- 1.06 oz.) 

  16. WARM UP ENGINE 
  17. INSPECT LEAKAGE OF REFRIGERANT (See  REPLACEMENT  ) 
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