Compressor & Magnetic Clutch: Reassembly

WARNING: This page is about a different car, the 2004 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL STATOR
1. Install the wire harness and lock sensor assembly with the 2 bolts and screw.
  
  Fig 1: Installing Wire Harness And Lock Sensor Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the stator.
  
  Fig 2: Installing Stator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using snap ring pliers, install the snap ring.
  
  Fig 3: Installing Snap Ring Using Snap Ring Pliers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: The snap ring should be installed so that its beveled side faces up.
  
  Fig 4: Locating Snap Ring Beveled Side Face Direction
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Connect the connector to the stator.
  
  Fig 5: Connecting Connector To Stator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ROTOR
1. Install the rotor.
2. Using snap ring pliers, install the snap ring.
  
  Fig 6: Installing Snap Ring Using Snap Ring Pliers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: The snap ring should be installed so that beveled side faces up.
  
  Fig 7: Locating Snap Ring Beveled Face Direction
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PRESSURE PLATE
1. Install the shims to the pressure plate and install the pressure plate on the rotor.
  
  Fig 8: Installing Shim To Pressure Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a torque wrench, install the shaft bolt.
  SST 07112-66040, 07112-76060
  
  Torque: 18 N.m (184 kgf.cm, 13.2 ft.lbf)
  
  Fig 9: Installing Shaft Bolt Using SST Torque Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT MAGNETIC CLUTCH CLEARANCE
1. Set the dial indicator to the pressure plate of the magnetic clutch.
2. Connect the positive (+) lead from the battery to the terminal 3 and the negative (-) lead to the ground.
3. Check the clearance between the pressure plate and rotor when connecting the negative (-) terminal to the battery.
  
  Fig 10: Inspecting Magnetic Clutch Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard clearance:
  
  0.45 + 0.15 mm (0.018 + 0.006 in.)
  
  0.45 - 0.10 mm (0.018 - 0.004 in.)
  
  If the clearance is not within the standard clearance, adjust the clearance using shims to obtain the standard clearance.
  
  Shim thickness:
  
  0.1 mm (0.004 in.)
  
  0.3 mm (0.012 in.)
  
  0.5 mm (0.020 in.)