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COOLER COMPRESSOR ASSY (ZZ E/G Series): Replacement

HINT:

  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 ENGINE UNDER COVER RH (2ZZ-GE ENGINE TYPE) (see  FAN AND GENERATOR V BELT (2ZZ-GE)  ) 
  3. REMOVE CYLINDER HEAD COVER NO. 2 (2ZZ-GE ENGINE TYPE) (see  FAN AND GENERATOR V BELT (2ZZ-GE)  ) 
  4. REMOVE WIRE HARNESS PROTECTOR (2ZZ-GE ENGINE TYPE) (see  FAN AND GENERATOR V BELT (2ZZ-GE)  ) 
  5. REMOVE AIR SWITCHING VALVE ASSY (2ZZ-GE ENGINE TYPE) (see  FAN AND GENERATOR V BELT (2ZZ-GE)  ) 
  6. REMOVE ENGINE UNDER COVER RH (1ZZ-FE ENGINE TYPE) (see  FAN AND GENERATOR V BELT (1ZZ-FE)  ) 
  7. DISCONNECT SUCTION HOSE SUB-ASSY 
    1. Remove the bolt and disconnect the suction hose sub-assy from the compressor and magnetic clutch.
    2. Remove the O-ring from the suction hose sub-assy.
    NOTE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
    Fig 1: Disconnecting Suction Hose
    G02615419Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. 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
    G02615420Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FAN AND GENERATOR V BELT (2ZZ-GE ENGINE TYPE) (see  FAN AND GENERATOR V BELT (2ZZ-GE)  ) 
  10. REMOVE FAN AND GENERATOR V BELT (1ZZ-FE ENGINE TYPE) (see  FAN AND GENERATOR V BELT (1ZZ-FE)  ) 
  11. REMOVE COMPRESSOR AND MAGNETIC CLUTCH 
    1. Disconnect the connector.
    2. Remove the 3 bolts and the compressor and magnetic clutch.
    Fig 3: Removing Compressor And Magnetic Clutch
    G02615421Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE MAGNET CLUTCH ASSY 
    1. Place the compressor and magnetic clutch in vise.
    2. Using SST remove the bolt.

      SST 95047-10400

    3. Remove the magnet clutch hub and magnet clutch washers.

      HINT:

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

      Fig 4: Removing Bolt Using SST
      G02615422Courtesy 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
      G02615423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a snap ring expander, remove the snap ring and magnet clutch stator.
    Fig 6: Removing Snap Ring
    G02615424Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL MAGNET CLUTCH ASSY 
    1. Matching the parts shown in the illustration, install the magnet clutch stator.
    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 7: Installing New Snap Ring
      G02615425Courtesy 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 8: Installing Magnet Clutch Rotor
      G02615426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using SST, secure the magnet clutch hub and tighten it with the bolt.

    SST 95047-10400

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

    NOTE: Ensure that there is no foreign matter or oil on the compressor shaft, bolt, and clutch hub.
    Fig 9: Securing Magnet Clutch Hub
    G02615427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSPECT MAGNETIC CLUTCH CLEARANCE 
    1. Set the dial indicator to the magnet clutch hub.
    2. Connect the battery positive lead to 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 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 10: Setting Dial Indicator To Magnet Clutch Hub
    G02615428Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. ADJUST 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 or equivalent for compressor oil.
  16. 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 11: Installing Compressor And Magnetic Clutch
    G02615429Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. 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) 

  18. INSTALL SUCTION 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 suction hose sub-assy.
      Fig 12: Installing O-Ring To Suction Hose
      G02615430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the suction 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 Suction Hose
    G02615431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL AIR SWITCHING VALVE ASSY (2ZZ-GE ENGINE TYPE) (see  FAN AND GENERATOR V BELT (2ZZ-GE)  ) 
  20. INSTALL CYLINDER HEAD COVER NO. 2 (2ZZ-GE ENGINE TYPE) (see  FAN AND GENERATOR V BELT (2ZZ-GE)  ) 
  21. 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: 480 +/- 30 g (16.9 +/- 1.06 oz.) 

  22. WARM UP ENGINE 
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