Compressor And Magnetic Clutch: Reassembly

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

INSTALL MAGNET CLUTCH ASSEMBLY
1. Install the magnet clutch stator with the parts shown in Fig 1.
  
  Fig 1: Installing Magnet Clutch Stator With Parts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, install a new snap ring with the chamfered side facing up.
  SST 95994-10020
3. Install the wire harness with the screw.
  
  Fig 2: Installing New Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, install the magnet clutch rotor and a new snap ring with the chamfered side facing up.
  SST 95994-10020
  
  NOTE: Take care not to damage the seal cover of the bearing when installing the snap ring.
5. Install the compressor spacer and magnet clutch hub.
  NOTE: Do not change the combination of the compressor spacer used before disassembly.
  
  Fig 3: Installing Magnet Clutch Rotor & New Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using SST, hold the magnet clutch hub and install the new bolt.
  SST 07112-76060
  
  Torque: 13.5 N*m (138 kgf*cm, 10 ft.*lbf)
  
  NOTE: Make sure that there is no foreign matter or oil on the compressor shaft, bolt, and clutch hub.
  
  HINT:
  
  Use new bolt (88329-04050) for clutch installation.
  
  Fig 4: Holding Magnet Clutch Hub & Installing New Bolt Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PRESSURE RELIEF VALVE
1. Install a new O-ring onto the pressure relief valve.
2. Install the pressure relief valve.
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
  
  Fig 5: Installing Pressure Relief Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COMPRESSOR PICK UP SENSOR
1. Install the compressor pick up sensor with the screw.
  Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
  
  Fig 6: Installing Compressor Pick Up Sensor With Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COOLER BRACKET
1. Install the cooler bracket with the screw.
2. Connect the 2 connectors.
  
  Fig 7: Installing Cooler Bracket With Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT MAGNET CLUTCH CLEARANCE
1. Clamp the compressor and magnetic clutch in a vise.
2. Set the dial indicator to the magnet clutch hub.
3. Connect the battery positive lead to terminal 1 (MG+) of the magnet clutch connector and the negative lead to the earth wire. Turn the magnet clutch on and off and measure the clearance.
  Standard clearance: 0.30 to 0.60 mm (0.012 to 0.024 in.)
  
  If the measured value is not within the standard clearance, remove the magnet clutch hub and adjust the clearance using compressor spacer to obtain the standard clearance.
  
  Compressor spacer thickness:
  
  0.2 mm (0.008 in.)
  
  0.3 mm (0.012 in.)
  
  0.5 mm (0.020 in.)
  
  NOTE: Adjustment should be performed with 3 or less magnet clutch washers.
4. Remove the compressor and magnetic clutch from the vise.
  
  Fig 8: Connecting Battery Positive Lead To Terminal 1 Of Magnet Clutch Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002