Cooler Compressor ASSY: Replacement

HINT:

COMPONENTS: See COOLER COMPRESSOR ASSY 

1. DRAIN REFRIGERANT (See  REPLACEMENT  ) 

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

2. SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 
   1. Remove the nut, 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: Cap the open fittings immediately to keep moisture or dirt out of the system.
   Fig 1: Separating Cooler Refrigerant Suction Hose No.1

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. SEPARATE COOLER REFRIGERANT DISCHARGE HOSE NO.1 
   1. Remove the nut, disconnect the cooler refrigerant discharge hose No. 1 from the compressor and magnet clutch.
   2. Remove the O-ring from the cooler refrigerant discharge hose No. 1.
   NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system.
   Fig 2: Separating Cooler Refrigerant Discharge Hose No.1

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. REMOVE FAN AND GENERATOR V BELT 
5. REMOVE ENGINE UNDER COVER 
6. REMOVE COMPRESSOR AND MAGNETIC CLUTCH 
   1. Disconnect the connector.
   2. Remove the 3 bolts.
      Fig 3: Removing Compressor And Magnetic Clutch

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Remove the nut, No. 1 compressor mounting bracket and compressor and magnetic clutch.
      Fig 4: Removing Nut Of Compressor Mounting Bracket

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. REMOVE MAGNET CLUTCH ASSY 
   1. Place the compressor and magnetic clutch in vise.
   2. Remove the 2 screws and bracket.
      Fig 5: Placing Compressor And Magnetic Clutch In Vise And Removing 2 Screws And Bracket

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Using SST, hold the magnet clutch hub.

      SST 07112-76060

   4. Remove the bolt, magnet clutch hub and 3 magnet clutch washers.
      Fig 6: Removing Magnet Clutch Assy

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   5. Using a snap ring expander, remove the snap ring and magnet clutch rotor.
   6. Disconnect the connector, remove the screw and earth wire.
      Fig 7: Using Snap Ring Expander, Remove Snap Ring And Magnet Clutch Rotor

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   7. Using a snap ring expander, remove the snap ring and magnet clutch stator.
      Fig 8: Using Snap Ring Expander, Remove Snap Ring And Magnet Clutch Stator

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. REMOVE COOLER COMPRESSOR ASSY 
9. INSTALL MAGNET CLUTCH ASSY 
   1. Matching the parts shown in Fig 9, install the magnet clutch stator.
      Fig 9: Installing Magnet Clutch Assy

      Courtesy 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 earth wire with the screw.
   4. Connect the connector.
      Fig 10: Using Snap Ring Expander, Install A New Snap Ring

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   5. Using a snap ring expander, install the magnet clutch rotor and a new snap ring with the chamfered side facing up.
   6. Install the magnet clutch washer and magnet clutch hub.
      NOTE: Do not change the combination of the magnet clutch washers used before disassembly.
      Fig 11: Using Snap Ring Expander, Install Magnet Clutch Rotor And A New Snap Ring

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

      SST 07112-76060

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

      Fig 12: Using SST, Hold Magnet Clutch Hub And Install Bolt

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   8. Install the 2 screws and bracket.
      Fig 13: Installing 2 Screws And Bracket

      Courtesy 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 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.) 

       Fig 14: Inspecting Magnetic Clutch Clearance With Dial Indicator<

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       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.
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: 120-135 ml) - (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 and No. 1 compressor mounting bracket.
    2. Temporarily tighten the nut.
       Fig 15: Installing Compressor And Magnetic Clutch

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 3 bolts to the compressor and magnetic clutch.

       Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 

    4. Tighten the nut.

       Torque: 29 N.m (300 kgf.cm, 21 ft.lbf) 

    5. Connect the connector.
       Fig 16: Installing The 3 Bolts To Compressor And Magnetic Clutch

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. INSTALL ENGINE UNDER COVER 
14. INSTALL FAN AND GENERATOR V BELT 
15. INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO. 1 
    1. Remove the attached vinyl tape from the hose.
    2. Lubricate a new O-ring with compressor oil, install them to the cooler refrigerant discharge hose No. 1.

       Compressor oil: ND-OIL 8 or equivalent 

    3. Connect the cooler refrigerant discharge hose No. 1 to the compressor and magnetic clutch, install the nut.

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

    Fig 17: Installing Cooler Refrigerant Discharge Hose No. 1

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 
    1. Remove the attached vinyl tape from the hose.
    2. Lubricate a new O-ring with compressor oil, install them to the cooler refrigerant suction hose No. 1.

       Compressor oil: ND-OIL 8 or equivalent 

    3. Connect the cooler refrigerant suction hose No. 1 to the compressor and magnetic clutch, install the nut.
       Fig 18: Installing Cooler Refrigerant Suction Hose No.1

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

17. 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: 600 +/- 50 g (21.16 +/- 1.76 oz.) 

18. WARM UP ENGINE 
19. INSPECT LEAKAGE OF REFRIGERANT (See  REPLACEMENT  )