COMPRESSOR AND MAGNETIC CLUTCH (for 1GR-FE): Reassembly

WARNING: This page is about a different car, the 2008 Toyota Tundra. 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 the illustration matched.
  
  Fig 1: Identifying 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.
3. Connect the connector.
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 damage the seal cover of the bearing when installing the snap ring.
  
  Fig 3: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the compressor washer(s) and magnet clutch hub.
  NOTE: Do not change the combination of the compressor washer(s) used before disassembly.
6. Using SST, hold the magnet clutch hub and install the bolt.
  SST 09985-00270
  
  Torque: 18 N*m (184 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 4: Installing Magnet Clutch Hub Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COOLER BRACKET
1. Install the cooler bracket with the screw.
2. Attach the clamp.
INSPECT MAGNET CLUTCH CLEARANCE
1. Clamp the cooler compressor in a vise.
2. Set the dial indicator to the magnet clutch hub.
3. Connect the battery positive lead to terminal 3 of the magnet clutch connector and the negative lead to the ground wire. Turn the magnet clutch on and off and measure the clearance.
  Standard clearance:
  
  0.35 to 0.60 mm (0.014 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 washers to obtain the standard clearance.
  
  Compressor washer thickness:
  
  0.1 mm (0.004 in.)
  
  0.3 mm (0.012 in.)
  
  0.5 mm (0.020 in.)
  
  NOTE: Adjustment should be performed with 3 or fewer magnet clutch washers.
  
  Fig 6: Checking Magnet Clutch Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the cooler compressor from the vise.