Repair Procedure
1. Evacuate the refrigerant HFC-134a (R-134a).Equipment: Robinair R-134a Refrigerant Recovery/Recycling Machine (P/N ACR2000)
2. Drain coolant.
3. Disconnect the cable from the negative (-) battery terminal.
4. Remove the condenser.
Follow the instructions for condenser removal in the Technical Information System (TIS), 2004 model year Sienna Repair Manual: Heater & Air Conditioner: Cooler Condenser Core: Replacement.
NOTE:
The replacement condenser will NOT be reinstalled until step 42.
5. Remove the compressor.
Procedure Follow the instructions for compressor removal in TIS, 2004 model year Sienna Repair Manual: Heater & Air Conditioner: Cooler Compressor Assembly: Replacement.
NOTE:
The replacement compressor will NOT be reinstalled until step 40.
6. Remove the engine moving control rod.
Follow the instructions in TIS, 2004 model year Sienna Repair Manual: Engine Mechanical: Timing Belt: Replacement (step 12).
7. Remove the suction hose sub-assembly.
8. Remove the cooler refrigerant liquid pipe E.
Remove front expansion valve:
9. Remove the air conditioning unit assembly.
Follow the instructions for air conditioning unit assembly removal in TIS, 2004 model year Sienna Repair Manual: Heater & Air Conditioner: Air Conditioning Radiator Assembly: Overhaul.
10. Remove the blower assembly from air conditioner box.
Remove the 2 screws and the blower assembly.
11. Remove cooling unit packing No. 3.
12. Remove the air conditioning tube assembly.
A. Using a hexagon wrench 4.0 mm, remove the 2 hexagon bolts and the air conditioning tube assembly.
B. Remove the 2 0-rings from the air conditioning tube assembly.
13. Remove the front expansion valve from the evaporator sub-assembly.
NOTE:
Inspect the expansion valve inlet and outlet for metal debris.
^ If metal debris is NOT found, reinstall the expansion valve.
^ If metal debris is found, replace the expansion valve.
14. Install the new expansion valve or reinstall the original expansion valve.
A. Sufficiently apply compressor oil to 2 NEW 0-rings and the fitting surface of the evaporator sub-assembly.
B. Install the expansion valve to the evaporator sub-assembly.
15. Reinstall the air conditioning unit assembly in reverse order.
Remove rear expansion valve:
16. Remove the back door scuff plate.
A. Remove the 3 bolts.
B. Using a screwdriver, disengage the 6 clips and remove the scuff plate.
HINT:
Tape the screwdriver tip before use.
17. Remove the quarter trim panel assembly front RH.
A. Remove the floor anchor cover.
B. Remove the bolt and disconnect the rear No. 2 seat belt on the floor anchor side.
C. Remove the 2 package holder net hooks.
D. Using a taped screwdriver, disengage the claw and the remove the courtesy lamp.
E. Disconnect the courtesy lamp connectors.
F. Using a taped screwdriver, disengage the 16 clips and remove the trim panel assembly.
18. Remove the 2 clamps attaching the coolant lines to the rear air conditioner box.
19. Remove the 2 bolts from the rear expansion valve.
20. Remove the 4 bolts from the A/C coolant line attaching plate.
21. Lift the vehicle in the air.
22. Remove RH/RR tire.
23. Remove the inner wheel well liner.
24. Separate the following A/C lines by removing the attaching nut.
^ Liquid pipe D from liquid pipe B
^ Suction pipe B from A/C tube
25. Remove the hose clamps from both coolant lines.
26. Remove the line assembly (liquid pipe D, air conditioner tube, and rear coolant lines from inside the vehicle).
27. Inspect the expansion valve inlet and outlet for metal debris.
NOTE:
Inspect the expansion valve inlet and outlet for metal debris.
^ If metal debris is NOT found, reinstall the expansion valve.
^ If metal debris is found, replace the expansion valve.
28. Remove the plastic line cover from underneath the vehicle.
29. Remove the nuts from the front line retainers.
30. Disconnect the evaporator drain tube from the A/C lines.
31. Release the clip from the middle of the lines.
32. Remove suction pipe A and liquid pipe C.
33. Remove the 3 retainer nuts from the rear heater lines.
34. Lower the rear coolant lines.
35. Remove suction pipe B and liquid pipe B.
36. To clean the line, use high pressure shop air to blow through the lines until NO debris is present.
NOTE:
^ Prior to blowing shop air through the A/C lines, let the lines vent for approximately 10 minutes.
^ If solvents are used as a cleaning agent, use only the solvents designed for A/C system cleaning.
37. Reassemble the rear HVAC in reverse order.
38. Install the new magnetic clutch assembly, only if damaged.
NOTE:
If NOT damaged, install the magnetic clutch from the original compressor.
A. Fit the part as shown in the illustration and install the magnetic clutch stator.
B. Using a snap ring expander, install a new snap ring with the chamfered side facing up.
C. Install the screw and connect the connector.
D. Using a snap ring expander, install the magnet clutch rotor and a new snap ring with chamfered side facing up.
E. Install the magnet clutch washer and the magnetic clutch hub.
F. Using the SST, install the magnetic clutch hub and the magnet clutch washer with the bolt.
^ SST P/N: 09960-10010
Torque: 18 N.m
(183 kgf.cm, 13 ft.lbf)
39. Inspect the magnetic clutch clearance.
A. Set the dial indicator to the magnetic clutch hub.
B. Connect the battery positive (+) lead to terminal 1 of the magnetic clutch connector and the negative (-) lead to ground. Turn on the magnetic clutch and measure the clearance.
Standard: 0.35 mm to 0.60 mm (0.013 in. to 0.023 in.)
If the measured value is NOT within the standard range, remove the magnetic clutch hub and adjust with the magnet clutch washers.
NOTE:
Adjustments should be performed with 3 or less magnetic clutch washers.
NOTE:
^ Since the compressor and condenser are both being replaced, the oil level should NOT need to be adjusted. The correct amount should already be in the compressor.
^ Standard: Oil capacity inside the new compressor and magnetic clutch: 120 cc + 15 cc (4.0 fl oz + 0.5 fl oz)
^ Be sure to use ND-OIL 8 for compressor oil.
40. Install the new compressor.
A. Install the compressor and the magnetic clutch, the stay, and bracket with the 2 bolts.
Torque: 24 N.m
(245 kgf.cm, 18 ft.lbf)
B. Install the 3 bolts.
Torque: 24 N.m
(245 kgf.cm, 18 ft.lbf)
C. Connect the 2 clamps and wire harness.
D. Connect the connector.
41. Install the new suction hose with filter.
42. Install the new cooler condenser core with the 2 bolts.
Torque: 3.9 N.m (40 kgf.cm, 18 in..lbf)
43. Connect the cable to the negative (-) battery terminal.
44. Refill the vehicle with coolant.
NOTE:
For additional information, refer to the instructions on the TIS, 2004 model year Sienna Repair Manual: Cooling: Engine Coolant: Replacement.
45. Charge refrigerant HFC-134a (R-134a).
Specified Amount: 780 +/- 30 g (27.5 +/- 1.06 oz)
Equipment: Robinair R-134a Refrigerant Recovery/Recycling Machine (P/N ACR2000)
46. Operate the A/C cycle for 10 minutes while the vehicle is idling.
Set up: Temperature - Max Cool (Front and Rear) Blower - High
47. Remove metal debris from the filter supplement.
A. Shut off the vehicle and evacuate the A/C system.
B. Remove the suction hose.
C. Remove the metal debris.
a. Blow shop air from the compressor side.
b. Blow shop air from the filter side.
D. Confirm that all metal debris has been removed and reinstall the suction tube.
48. Recharge the system.
49. Warm up the engine.
50. Check for refrigerant leakage and verify A/C performance.
51. Check for coolant leakage.
52. Initialize power Systems.
^ 2004 model year Sienna vehicles:
To initialize power Systems, refer to TSB No. PG002-03, "Pre-Delivery Service (PDS) Information for Sienna."
^ 2005 model year Sienna vehicles:
To initialize power systems, refer to TSB No. PD008-05, "Power System Initialization During PDS."