Cooler Compressor ASSY (2AZ-FE): Replacement

HINT:

COMPONENTS: See COMPONENTS 

1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See  REPLACEMENT  ) 
2. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See  REPLACEMENT  ) 
3. REMOVE GENERATOR ASSY (See  GENERATOR  ) 
4. DISCONNECT COOLER REFRIGERANT DISCHARGE HOSE NO.1 
   1. Remove the nut and disconnect the cooler refrigerant discharge hose No.1.
   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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO.1 
   1. Remove the nut and disconnect the cooler refrigerant suction hose No.1.
   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 2: Disconnecting Cooler Hose

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. REMOVE COMPRESSOR AND MAGNETIC CLUTCH 
   1. Disconnect the connector.
   2. Remove the nut.
      Fig 3: Removing Nut

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Using a E8 torque socket wrench, remove the stud bolt.
      Fig 4: Removing Stud Bolt With Using E8 Torque Socket Wrench

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Remove the 3 bolts and compressor and magnetic clutch.
   Fig 5: Removing Bolts From Compressor

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. REMOVE MAGNET CLUTCH ASSY 
   1. Remove the bolt and the bracket.
   2. Place the compressor and magnetic clutch in a vise.
      NOTE: Do not get the bracket and harness caught in the vise.
      Fig 6: Removing Bolt Or Bracket

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Using SST, hold the magnet clutch hub. SST 95047-10400
   4. Remove the bolt, magnet clutch hub and magnet clutch washer.

      HINT:

      There is no set number of magnet clutch washers since they are used for adjusting.

      Fig 7: Holding Magnet Clutch Hub

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   5. Using a snap ring expander, remove the snap ring and magnet clutch rotor.
      NOTE: Do not damage the seal cover of the bearing when removing the snap ring.
   6. Remove the screw and disconnect the connector.
      Fig 8: Removing Screw Or Disconnect Connector

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   7. Using a snap ring expander, remove the snap ring and magnet clutch stator.
   Fig 9: Removing Snap Ring Or Magnet Clutch Stator

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. INSTALL MAGNET CLUTCH ASSY 
   1. Fit the parts as shown in the illustration and install the magnet clutch stator.
      Fig 10: Installing Magnet Clutch Stator

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using a snap ring expander, install a new snap ring with the chamfered side facing up.
      NOTE: Do not damage the seal cover of the bearing when removing the snap ring.
   3. Install the screw and connect the connector.
      Fig 11: Installing A New Snap Ring With Chamfered Side Facing Up

      Courtesy 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.
      NOTE:

      • Do not expand the snap ring by more than 30.5 mm (1.2 in) when installing it.
      • Do not damage the seal cover of the bearing when removing the snap ring.
   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 12: Installing Magnet Clutch Washer Or Magnet Clutch Hub

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   6. Using SST, hold the magnet clutch hub and install the bolt.

      SST 95047-10400

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

   NOTE: Make sure that there is no foreign matter or oil on the compressor shaft, bolt, and clutch hub.
   Fig 13: Installing Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. INSPECT MAGNETIC CLUTCH CLEARANCE 
   1. Set the dial gage to the magnet clutch hub.
   2. Connect the positive battery lead to terminal 3 of the 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 to 0.60 mm (0.013 to 0.023 in.) 

      If the measured value is not within the standard range, remove the magnet clutch hub and adjust it with magnet clutch washers.

      Fig 14: Adjusting Dial Gauge To Magnet Clutch Hub

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Adjustment shall be performed with 3 or less magnet clutch washers.
   3. Remove the compressor and magnetic clutch from the vise.
   4. Install bracket with the bolt.
   Fig 15: Installing Bracket With Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. 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 cooler compressor assy: 120 + 15 cc (4.06 + 0.5 fl.oz.)) - (Remaining oil amount in the removed cooler compressor assy) = (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 cooler compressor assy 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 cooler compressor assy is too small in volume, check for oil leakage.
    • Be sure to use ND-OIL8 for compressor oil.
11. TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH 
    1. Temporarily tighten the compressor and magnetic clutch with the stud bolt.
    Fig 16: Installing Compressor With Bolt

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. FULLY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH 
    1. Fully tighten the compressor and magnetic clutch with the 3 bolts and nut.

       Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf) 

       NOTE: Tighten them in the order indicated in the illustration.
    2. Connect the connector.
    Fig 17: Installing Compressor Or Magnetic Clutch With Bolts Or Nut

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 
    1. Remove the attached vinyl tape from the hose.
    2. Sufficiently apply compressor oil to the O-ring and fit surface of the compressor and magnetic clutch.
    3. Install a new O-ring to the cooler refrigerant suction hose No.1.

       Compressor oil: ND-OIL 8 or equivalent 

       Fig 18: Installing O-Ring To Suction Hose

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.Vlbf) 

    Fig 19: Installing Cooler Suction Hose

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO.1 
    1. Remove the attached vinyl tape from the hose.
    2. Sufficiently apply compressor oil to the O-ring and fit surface of the compressor and magnetic clutch.
    3. Install a new O-ring to the cooler refrigerant discharge hose No.1.

       Compressor oil: ND-OIL 8 or equivalent 

       Fig 20: Installing O-Ring To Cooler Refrigerant Discharge Hose

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.Vlbf) 

    Fig 21: Installing Compressor Or Magnetic Clutch With Nut

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. INSTALL BELT, V-RIBBED (See  REPLACEMENT  ) 
16. INSTALL GENERATOR ASSY (See  GENERATOR  ) 
17. CHARGE REFRIGERANT (See  REPLACEMENT  ) 
18. WARM UP ENGINE (See  REPLACEMENT  ) 
19. INSPECT LEAKAGE OF REFRIGERANT (See  REPLACEMENT  )