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Compressor And Magnetic Clutch: Reassembly

WARNING: This page is about a different car, the 2006 Scion tC. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL MAGNET CLUTCH ASSEMBLY 
    1. Matching the parts shown in the illustration, install the magnet clutch starter.
      Fig 1: Installing Magnet Clutch Starter
      G04223607Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a snap ring expander, install 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.
    3. Connect the connector.
      Fig 2: Installing Snap Ring With Chamfered Side Facing Up
      G04223608Courtesy 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.
      NOTE:
      • Do not expand the snap ring by more than 30.5 mm (1.2 in.) when installing it.
      • Do not damage the seal cover of the bearing when installing the snap ring.
      Fig 3: Installing Magnet Clutch Rotor And A New Snap Ring With Chamfered Side Facing Up
      G04223609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the magnet clutch washer and magnet clutch hub.
      NOTE: Do not change the combination of the magnet clutch washers used before disassembly.
    6. Using SST, hold the magnet clutch hub and install the bolt.

      SST 95047-10400 

      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.
  2. INSPECT MAGNETIC CLUTCH CLEARANCE 
    1. Set the dial indicator to the magnet clutch hub.
    2. Connect the battery positive (+) lead to the terminal 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: 0.35 to 0.60 mm (0.014 to 0.023 in.) 

      If the measured value is not within the standard range, remove the magnet clutch hub and adjust it with magnet clutch washers.

      NOTE: Adjustment should be performed with 3 or less magnet clutch washers.
    3. Remove the compressor and magnetic clutch from the vise.
    Fig 4: Setting Dial Indicator To Magnet Clutch Hub
    G04223610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. ADJUST COMPRESSOR OIL 
    1. When replacing the cooler compressor with a new one, after gradually removing the refrigerant gas from the service valve, drain the following amount of oil from the new cooler compressor before installation.

      Standard: (Oil capacity inside new cooler compressor: 140 + 15 cc (4.7 + 0.5 fl. oz.) ) - (Remaining oil amount in the removed cooler compressor) = (Oil amount to be removed when replacing) 

      NOTE:
      • When checking the compressor oil level, observe the precautions for the cooler removal/installation.
      • Since compressor oil remains in the pipes of the vehicle, if a new cooler compressor is installed without removing some oil inside, the oil amount becomes excessive, preventing heat exchange in the refrigerant cycle and causing refrigerant failure.
      • If the remaining oil in the removed cooler compressor is too small in volume, check for oil leakage.
      • Be sure to use ND-OIL 8 for compressor oil.
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