Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Toyota Sienna 2004-2007 Approved SRM 26 20tve x040001
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55-50
HEATER & AIR CONDITIONER - COOLER COMPRESSOR ASSY
550Y7-02
REPLACEMENT
HINT:
COMPONENTS: See page 55-49
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM(See page 55-21 )
SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070,
07117-88080)
2. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 55-29 )
3. DISCONNECT OIL COOLER INLET HOSE NO.1
(a) Using pliers, grip the claws of the clip side to disconnect
the oil cooler inlet hose No.1.
I35848
4. DISCONNECT OIL COOLER OUTLET HOSE NO.1
HINT:
Disconnection of the oil cooler outlet hose No.1 is the same way as the oil cooler inlet hose No.1.
5. REMOVE FAN ASSY W/MOTOR
(a) Release the 3 clamps.
(b) Disconnect the connectors.
3 Clamps I35472
(c) Remove the 4 bolts and the fan assy w/ motor.
I35473
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2976
55-51
HEATER & AIR CONDITIONER - COOLER COMPRESSOR ASSY
6. DISCONNECT DISCHARGE HOSE SUB-ASSY
(a) Remove the nut and disconnect the discharge hose sub-
assy from the compressor and magnetic clutch.
(b) Remove the O-ring from the discharge hose sub-assy.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matters from entering.
I35746
7. DISCONNECT SUCTION HOSE SUB-ASSY
(a) Remove the nut and disconnect the suction hose sub-
assy from the compressor and magnetic clutch.
(b) Remove the O-ring from the suction hose sub-assy.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matters from entering.
I35747
8. REMOVE COMPRESSOR AND MAGNETIC CLUTCH
(a) Disconnect the connector.
(b) Release the 2 clamps and wire harness.
2 Clamps I35474
(c) Remove the 3 bolts and the cooler compressor bracket.
I35475
(d) Remove the 2 bolts, the stay, and the compressor and
magnetic clutch.
I35476
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2977
55-52
HEATER & AIR CONDITIONER - COOLER COMPRESSOR ASSY
9. REMOVE MAGNET CLUTCH ASSY
(a) Place the compressor and magnetic clutch in a vise.
(b) Using SST, remove the bolt, the magnet clutch hub and
the magnet clutch washer.
SST 09960-10010 (09962-01000, 09963-00500)
I35477
(c) Using a snap ring expander, remove the snap ring and the
magnet clutch rotor.
(d) Remove the screw and disconnect the connector.
E37091
(e) Using a snap ring expander, remove the snap ring and the
magnet clutch starter.
E50116
10. REMOVE COOLER COMPRESSOR ASSY
11. INSTALL MAGNET CLUTCH ASSY
(a) Fit the parts as shown in the illustration and install the
magnet clutch starter.
I32460
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2978
55-53
HEATER & AIR CONDITIONER - COOLER COMPRESSOR ASSY
(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.
I32461
(d) Using a snap ring expander, install the magnet clutch ro-
tor and a new snap ring with the chamfered side facing up.
(e) Install the magnet clutch washer and the magnet clutch
hub.
NOTICE:
Do not change the combination of the magnet clutch wash-
ers used before disassembly.
I31582
(f) Using SST, install the magnet clutch hub and the magnet
clutch washer with the bolt.
SST 09960-10010 (09962-01000, 09963-00500)
Torque: 18 Nm (183 kgfcm, 13 ftlbf)
I35478
12. INSPECT MAGNETIC CLUTCH CLEARANCE
(a) Set the dial indicator to the magnet clutch hub.
(b) Connect the battery positive lead to the terminal 1 of the
magnet clutch connector and the negative lead to the
earth wire. Turn on and off the magnet clutch and mea-
sure the clearance.
Standard clearance:
0.35 to 0.60 mm (0.013 to 0.023 in.)
I35479 If the measured value is not within the standard range, remove
the magnet clutch hub and adjust it with the magnet clutch
washers.
NOTICE:
Adjustment can be performed with 3 or less magnet clutch
washers.
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2979
55-54
HEATER & AIR CONDITIONER - COOLER COMPRESSOR ASSY
13. INSPECT COMPRESSOR OIL
(a) When replacing the compressor and magnetic clutch with a new one, after gradually removing the re-
frigerant gas from the service valve, drain the following amount of oil from the new compressor and
magnetic clutch before installation.
Standard:
(Oil capacity inside new compressor and magnetic clutch: 120 + 15 cc (4.0 + 0.5 fl. oz.) ) - (Re-
maining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be re-
moved when replacing)
NOTICE:
S When checking the compressor oil level, observe the precautions on the cooler removal/instal-
lation.
S Because compressor oil remains in the pipes of the vehicle, if a new compressor and magnetic
clutch is installed without removing some oil inside, the oil amount becomes excessive, pre-
venting heat exchange in the refrigerant cycle and causing refrigerant failure.
S If the remaining oil in the removed compressor and magnetic clutch is too small in volume,
check for oil leakage.
S Be sure to use ND-OIL 8 for compressor oil.
(1) (2)
14. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
(a) Install the compressor, the magnetic clutch, the stay and
cooler compressor bracket with the 2 bolts.
Torque: 24 Nm (245 kgfcm, 18 ftlbf)
I36024
(2)
(b) Install the 3 bolts.
(1)
Torque: 24 Nm (245 kgfcm, 18 ftlbf)
I36014
I37095
(c) Connect the 2 clamps and wire harness.
(d) Connect the connector.
2 Clamps
I35474
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2980
55-55
HEATER & AIR CONDITIONER - COOLER COMPRESSOR ASSY
15. INSTALL SUCTION HOSE SUB-ASSY
(a) Remove the attached vinyl tape from the hose.
(b) Sufficiently apply compressor oil to a new O-ring and the
fitting surface of the compressor and magnetic clutch.
Compressor oil: ND-OIL 8 or equivalent
(c) Install the O-ring on the suction hose sub-assy.
(d) Install the suction hose sub-assy on the compressor and
magnetic clutch with the nut.
Torque: 5.4 Nm (55 kgfcm, 48 in.lbf)
16. INSTALL DISCHARGE HOSE SUB-ASSY
(a) Remove the attached vinyl tape from the hose.
(b) Sufficiently apply compressor oil to a new O-ring and the
fitting surface of the compressor and magnetic clutch.
Compressor oil: ND-OIL 8 or equivalent
I35747 (c) Install the O-ring on the discharge hose sub-assy.
(d) Install the discharge hose sub-assy on the compressor
and magnetic clutch with the nut.
Torque: 5.4 Nm (55 kgfcm, 48 in.lbf)
I35746
17. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 55-29 )
18. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 55-29 )
19. FULLY TIGHTEN V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 55-29 )
20. CHARGE REFRIGERANT (See page 55-21 )
SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050,
07117-88060, 07117-88070, 07117-88080)
Specified amount: 780 " 30 g (27.5 " 1.06 oz.)
21. WARM UP ENGINE
22. INSPECT LEAKAGE OF REFRIGERANT (See page 55-21 )
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2981
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