Compressor And Magnetic Clutch: Replacement

WARNING: This page is about a different car, the 2007 Lexus SC 430. However, it is still accessible from the selected car via links, so may be relevant.

DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See REPLACEMENT )
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE
1. Remove the nut and disconnect the suction hose from the compressor.
2. Remove the O-ring from the suction hose.
  NOTE: Keep the system free from moisture or foreign matter.
  
  HINT:
  
  Cover the openings of the hoses with vinyl tape immediately after disconnecting.
  
  Fig 1: Identifying Suction Hose Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE
1. Remove the nut and disconnect the discharge hose from the compressor.
2. Remove the O-ring from the discharge hose.
  NOTE: Keep the system free from moisture or foreign matter.
  
  HINT:
  
  Cover the openings of the hoses with vinyl tape immediately after disconnecting.
  
  Fig 2: Identifying Discharge Hose With Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FAN AND GENERATOR V BELT (See REMOVAL )
REMOVE ENGINE UNDER COVER (See ON-VEHICLE INSPECTION )
REMOVE COMPRESSOR AND MAGNETIC CLUTCH
1. Disconnect the connector.
2. Remove the 3 bolts.
  
  Fig 3: Identifying Compressor And Magnetic Clutch Connector And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the nut, No. 1 compressor mounting bracket and compressor.
  
  Fig 4: Identifying No. 1 Compressor Mounting Bracket Nut And Compressor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MAGNETIC CLUTCH ASSEMBLY
1. Place the compressor and magnetic clutch in vise.
2. Remove the 2 screws and bracket.
  
  Fig 5: Identifying Magnetic Clutch Assembly Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, hold the magnetic clutch hub.
  SST 07112-76060
4. Remove the bolt, magnetic clutch hub and 3 magnetic clutch washers.
  HINT:
  
  The 3 washers removed in this step will be reused during installation. Keep them together as a set.
  
  Fig 6: Holding Magnetic Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a snap ring expander, remove the snap ring and magnetic clutch rotor.
6. Disconnect the connector and remove the screw and ground wire.
  
  Fig 7: Removing Snap Ring And Magnetic Clutch Rotor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using a snap ring expander, remove the snap ring and magnetic clutch stator.
  
  Fig 8: Removing Snap Ring And Magnetic Clutch Stator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE COOLER COMPRESSOR ASSEMBLY
INSTALL MAGNETIC CLUTCH ASSEMBLY
1. Install the magnetic clutch stator by aligning it to the cooler compressor as shown in the illustration.
  
  Fig 9: Installing Magnetic Clutch Stator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a snap ring expander, install a new snap ring with the chamfered side facing upward.
3. Install the ground wire with the screw.
4. Connect the connector.
  
  Fig 10: Installing Snap Ring With Chamfered Side Facing Upward
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a snap ring expander, install the magnetic clutch rotor and a new snap ring with the chamfered side facing upward.
6. Install the 3 magnetic clutch washers and magnetic clutch hub.
  NOTE: Reuse the 3 washers removed in the "REMOVE MAGNETIC CLUTCH ASSEMBLY" procedures. This is necessary to maintain the clearance between the magnetic clutch hub and magnetic clutch rotor.
  
  Fig 11: Installing Magnetic Clutch Rotor And Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using SST, hold the magnetic clutch hub and install the bolt.
  SST 07112-76060
  
  Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
  
  Fig 12: Holding Magnetic Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Install the bracket with the 2 screws.
  
  Fig 13: Identifying Bracket With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT MAGNETIC CLUTCH CLEARANCE
1. Set the dial indicator to the magnetic clutch hub.
2. Connect the battery's positive (+) lead to terminal 3 of the magnetic clutch connector and the negative (-) lead to the earth wire. Turn on and off the magnetic clutch and measure the clearance.
  Standard clearance: 0.35 to 0.60 mm (0.014 to 0.024 in.)
  
  If the measured value is out of the standard range, remove the magnetic clutch hub and adjust it with magnetic clutch washers.
  
  Fig 14: Setting Dial Indicator To Magnetic Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Adjustment should be performed with 3 or less magnetic clutch washers.
3. Remove the compressor from the vise.
INSPECT COMPRESSOR OIL
1. When replacing the compressor with new one, first gradually discharge the refrigerant gas from the service valve, and then drain the following amount of oil from the new compressor before installation.
  Standard: (Oil capacity inside new compressor: 120 + 15 cc (4.0 + 0.5 fl. oz.)) - (Remaining oil amount in the removed compressor) = (Oil amount to be removed when replacing)
  NOTE:
  - When checking the compressor oil level, follow the A/C system precautions
  - When installing a new compressor and magnetic clutch, the specified amount of oil must be removed from the new compressor. If the sum of the new compressor's oil and residual compressor's oil (remaining in the vehicle's pipes) is excessive, refrigerant cycle heat exchange problems will occur and the refrigerant system will not function properly.
  - If the remaining oil in the removed compressor is too low, check for oil leakage.
  - Be sure to use ND-OIL8 compressor oil.
INSTALL COMPRESSOR AND MAGNETIC CLUTCH
1. Temporarily install the compressor and No. 1 compressor mounting bracket with the nut.
  
  Fig 15: Identifying No. 1 Compressor Mounting Bracket With Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 3 bolts to the compressor and magnetic clutch.
  
  Fig 16: Identifying Compressor And Magnetic Clutch Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
3. Tighten the nut.
  Torque: 29 N*m (300 kgf*cm, 21 ft.*lbf)
4. Connect the connector.
INSTALL ENGINE UNDER COVER (See INSPECTION )
INSTALL FAN AND GENERATOR V BELT (See INSTALLATION )
INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE
1. Remove the vinyl tape attached to the hose.
2. Sufficiently apply compressor oil to a new O-ring and the contact surface of the discharge hose.
  Compressor oil: ND-OIL 8 or equivalent
3. Connect the discharge hose to the compressor with the nut.
  Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf)
  
  Fig 17: Identifying Discharge Hose To Compressor With Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE
1. Remove the vinyl tape attached to the hose.
2. Sufficiently apply compressor oil to a new O-ring and the contact surface of the suction hose.
  Compressor oil: ND-OIL 8 or equivalent
3. Connect the suction hose to the compressor with the nut.
  Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf)
  
  Fig 18: Identifying Suction Hose Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
PERFORM INITIALIZATION
1. Perform initialization (see INITIALIZATION ).
  NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
CHARGE REFRIGERANT (See REPLACEMENT )
WARM UP ENGINE (See REPLACEMENT )
CHECK FOR LEAKAGE OF REFRIGERANT (See REPLACEMENT )