Compressor HVAC: Service and Repair
Cooler Compressor Assy (2TR-FE):
Cooler Compressor Assy (1GR-FE):
COOLER COMPRESSOR ASSEMBLY
REPLACEMENT
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070,07117-88080)
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE FRONT WHEEL LH
4. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY NO.1
5. REMOVE V-BANK COVER (1GR-FE ENGINE TYPE)
6. REMOVE RADIATOR SUPPORT TO FRAME SEAL LH (1GR-FE ENGINE TYPE)
7. REMOVE FAN SHROUD (1GR-FE ENGINE TYPE)
8. REMOVE FAN AND GENERATOR V BELT
9. REMOVE GENERATOR ASSEMBLY (1GR-FE ENGINE TYPE)
10. REMOVE FRONT FENDER APRON SEAL UPPER
a. Using a clip remover, disengage the 5 clips and remove the front fender apron seal upper. (4WD, PRE RUNNER)
b. Using a clip remover, disengage the 6 clips and remove the front fender apron seal upper. (2WD)
11. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (2TR-FE ENGINE TYPE)
a. Remove the bolt and separate the suction hose sub-assembly.
b. Remove the bolt and disconnect the suction hose subassembly.
c. Remove the seal washer from the suction hose sub-assembly.
NOTE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
12. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (1GR-FE ENGINE TYPE)
a. Remove the bolt and separate the suction hose sub-assembly.
b. Remove the bolt and disconnect the suction hose subassembly.
c. Remove the seal washer from the suction hose sub-assembly.
NOTE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
13. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY
a. Remove the bolt and disconnect the cooler refrigerant discharge hose sub-assembly.
b. Remove the seal washer from the cooler refrigerant discharge hose sub-assembly.
NOTE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
14. REMOVE COMPRESSOR AND MAGNETIC CLUTCH (2TR-FE ENGINE TYPE)
a. Disconnect the connector.
b. Remove the 4 bolts and harness bracket, and remove the cooler compressor and magnetic clutch.
15. REMOVE COMPRESSOR AND MAGNETIC CLUTCH (1GR-FE ENGINE TYPE)
a. Disconnect the connector.
b. Remove the 4 bolts and cooler compressor and magnetic clutch.
16. REMOVE COOLER BRACKET
a. Disconnect the 2 connectors.
b. Remove the screw and the cooler bracket.
17. REMOVE COMPRESSOR PICK UP SENSOR
a. Remove the screw and the compressor pick up sensor.
18. REMOVE PRESSURE RELIEF VALVE
a. Remove the pressure relief valve and O-ring.
19. REMOVE MAGNET CLUTCH ASSEMBLY
a. Using SST, hold the magnet clutch hub.
SST 07112-76060
b. Remove the bolt, magnet clutch hub and compressor spacer.
HINT: There is no set number of magnet clutch washers since they are used for adjusting.
c. Using SST, remove the snap ring and magnet clutch rotor.
SST 95994-10020
NOTE: Take care not to damage the seal cover of the bearing when removing the snap ring.
d. When the magnet clutch rotor and snap ring are difficult to remove, use a plastic hammer to tap them off the shaft.
NOTE: Be careful not to damage the pulley when tapping the rotor.
e. Remove the screw and separate the wire harness.
f. Using SST, remove the snap ring and magnet clutch stator.
SST 95994-10020
20. INSTALL MAGNET CLUTCH ASSEMBLY
a. Install the magnet clutch stator with the parts shown in the illustration matched.
b. Using SST, install a new snap ring with the chamfered side facing up.
SST 95994-10020
c. Install the wire harness with the screw.
d. 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.
e. Install the compressor spacer and magnet clutch hub.
NOTE: Do not change the combination of the compressor spacer used before disassembly.
f. 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.
21. INSTALL PRESSURE RELIEF VALVE
a. Install a new O-ring onto the pressure relief valve.
b. Install the pressure relief valve.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
22. INSTALL COMPRESSOR PICK UP SENSOR
a. Install the compressor pick up sensor with the screw.
Torque: 4.0 N.m (41 kgf.cm, 35 in.lbf)
23. INSTALL COOLER BRACKET
a. Install the cooler bracket with the screw.
b. Connect the 2 connectors.
24. INSPECT MAGNETIC CLUTCH CLEARANCE
a. Clamp the compressor and magnetic clutch in a vise.
b. Set the dial indicator to the magnet clutch hub.
c. 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.
d. Remove the compressor and magnetic clutch from the vise.
25. ADJUST COMPRESSOR OIL
a. When replacing the compressor and magnetic clutch with new ones, after gradually discharging the refrigerant gas from the service valve, drain the following volume of oil from new compressor and magnetic clutch before installation.
Standard:
(Oil capacity inside a new compressor and magnetic clutch: 150 + 15 cc (5.1 + 0.51 fl.oz.)) - (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed when replacing the compressor)
NOTE:
- When checking the compressor oil level, observe the precautions on the cooler removal/installation.
- If a new compressor and magnetic clutch are installed without removing some oil remaining in the pipes of the vehicle, the oil amount becomes too large. This prevents heat exchange in the refrigerant cycle and causes refrigerant failure.
- If the volume of oil remaining in the removed compressor and magnetic clutch is too small, check for oil leakage.
- Be sure to use RL-897 for compressor oil.
26. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (1GR-FE ENGINE TYPE)
a. Provisionally tighten the compressor and magnetic clutch with the 4 bolts.
b. Tighten the compressor and magnetic clutch with the 4 bolts.
Torque: 21 N.m (214 kgf.cm, 16 ft.lbf)
NOTE: Tighten the bolts in the sequence order shown in the illustration to install the compressor and magnetic clutch.
c. Connect the connector.
27. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (2TR-FE ENGINE TYPE)
a. Provisionally tighten the compressor and magnetic clutch with the 4 bolts and harness bracket.
NOTE: The harness bracket stopper should be in contact with compressor case.
b. Tighten the compressor and magnetic clutch with the 4 bolts.
Torque: 21 N.m (214 kgf.cm, 16 ft.lbf)
NOTE: Tighten the bolts in the sequence order shown in the illustration to install the compressor and magnetic clutch.
c. Connect the connector.
28. INSTALL DISCHARGE HOSE SUB-ASSEMBLY
a. Remove the attached vinyl tape from the hose.
b. Apply sufficient compressor oil to a new seal washer and fitting surface of the compressor and magnetic clutch.
Compressor oil: RL-897 or equivalent
c. Install the seal washer onto the cooler refrigerant discharge hose sub-assembly.
d. Install the cooler refrigerant discharge hose sub-assembly onto the compressor and magnetic clutch with the bolt.
Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
29. INSTALL SUCTION HOSE SUB-ASSEMBLY (1GR-FE ENGINE TYPE)
a. Remove the attached vinyl tape from the hose.
b. Apply sufficient compressor oil to a new seal washer and fitting surface of the compressor and magnetic clutch.
Compressor oil: RL-897 or equivalent
c. Install the seal washer onto the suction hose sub-assembly.
d. Install the suction hose sub-assembly onto the compressor and magnetic clutch with the bolt.
Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
e. Install the suction hose sub-assembly with the bolt.
Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)
30. INSTALL SUCTION HOSE SUB-ASSEMBLY (2TR-FE ENGINE TYPE)
a. Remove the attached vinyl tape from the hose.
b. Apply sufficient compressor oil to a new seal washer and fitting surface of the compressor and magnetic clutch.
Compressor oil: RL-897 or equivalent
c. Install the seal washer onto the suction hose sub-assembly.
d. Install the suction hose sub-assembly onto the compressor and magnetic clutch with the bolt.
Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
e. Install the suction hose sub-assembly with the bolt.
Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)
31. INSTALL FRONT FENDER APRON SEAL UPPER
a. Install the front fender apron seal upper with the 5 clips.(4WD, PRE RUNNER)
b. Install the front fender apron seal upper with the 6 clips.(2WD)
32. INSTALL GENERATOR ASSEMBLY (1GR-FE ENGINE TYPE)
33. INSTALL FAN AND GENERATOR V BELT
34. INSTALL FAN SHROUD (1GR-FE ENGINE TYPE)
35. INSTALL RADIATOR SUPPORT TO FRAME SEAL LH (1GR-FE ENGINE TYPE)
36. INSTALL V-BANK COVER (1GR-FE ENGINE TYPE)
37. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY NO.1
38. INSTALL FRONT WHEEL LH
Torque: 113 N.m (1152 kgf.cm, 83 ft.lbf)
39. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 3.9 N.m (40 kgf.cm, 35 in.lbf)
40. CHARGE REFRIGERANT
Specified amount: 600 ± 30 g (21.16 ± 1.06 oz.)
SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050,07117-88060, 07117-88070, 07117-88080), 07117-48130, 07117-48140
41. WARM UP ENGINE
42. CHECK FOR REFRIGERANT LEAKAGE