55–34
HEATER & AIR CONDITIONER – COOLER COMPRESSOR ASSY
550J0–01
REPLACEMENT
HINT:
COMPONENTS: See page 55–33
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page 55–11)
SST 07110–58060 (07117–58080, 07117–58090, 07117–78050, 07117–88060, 07117–88070,
07117–88080)
2. DISCONNECT COOLER REFRIGERANT SUCTION
HOSE NO.1
(a) Remove the bolt and disconnect the cooler refrigerant
suction hose No. 1 from the compressor and magnetic
clutch.
(b) Remove the O–ring from the cooler refrigerant suction
hose No. 1.
NOTICE:
I32458 Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matter from entering.
3. DISCONNECT DISCHARGE HOSE SUB–ASSY
(a) Remove the bolt 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 matter from entering.
I32459
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE FAN AND GENERATOR V BELT (See page 14–4)
6. REMOVE COMPRESSOR AND MAGNETIC CLUTCH
(a) Disconnect the connector.
(b) Remove the 3 bolts and compressor and magnetic clutch.
I32421
7. REMOVE MAGNET CLUTCH ASSY
(a) Place the compressor and magnetic clutch in vise.
2004 COROLLA (RM1037U)
Author: Date: 1604
55–35
HEATER & AIR CONDITIONER – COOLER COMPRESSOR ASSY
(b) Using a vise pliers, hold the magnet clutch hub.
(c) Remove the bolt, magnet clutch hub and magnet clutch
washer.
I32422
(d) Using a snap ring expander, remove the snap ring and
magnet clutch rotor.
(e) Remove the screw, disconnect the connector.
E37091
(f) Using a snap ring expander, remove the snap ring and
magnet clutch starter.
E50116
8. REMOVE COOLER COMPRESSOR ASSY
9. INSTALL MAGNET CLUTCH ASSY
(a) Matching the parts shown in the illustration, install the
magnet clutch starter.
I32460
2004 COROLLA (RM1037U)
Author: Date: 1605
55–36
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, 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 magnet clutch hub.
NOTICE:
Do not change the combination of the magnet clutch wash-
ers used before disassembly.
I31582
(f) Using a vise pliers, hold the magnet clutch hub and install
the bolt.
Torque: 18 N⋅m (183 kgf⋅cm, 13 ft⋅lbf)
I32423
10. 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 mag-
net clutch connector and the negative lead to the earth
wire. Turn on and off the magnet clutch and measure the
clearance.
Standard clearance:
0.35 – 0.60 mm (0.013 – 0.023 in.)
I32424 If the measured value is out of the standard range, remove the
magnet clutch hub and adjust it with magnet clutch washers.
NOTICE:
Adjustment shall be performed with 3 or less magnet
clutch washers.
2004 COROLLA (RM1037U)
Author: Date: 1606
55–37
HEATER & AIR CONDITIONER – COOLER COMPRESSOR ASSY
11. INSPECT COMPRESSOR OIL
(a) When replacing the compressor and magnetic clutch with new one, after gradually removing the refrig-
erant gas from the service valve, drain the following amount of oil from the new compressor and mag-
netic 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:
When checking the compressor oil level, observe the precautions on the cooler removal/instal-
lation.
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 too much, pre-
venting heat exchange in the refrigerant cycle and causing refrigerant failure.
If the remaining oil in the removed compressor and magnetic clutch is too small in volume,
check for oil leakage.
Be sure to use ND–OIL8 for compressor oil.
12. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
(a) Install the compressor and magnetic clutch with the 3
bolts.
(1) Toque: 29 N⋅m (295 kgf⋅cm, 21 ft⋅lbf)
NOTICE:
(2) Tighten the bolts in following order shown in the illustra-
tion to install the compressor and magnetic clutch.
(3) (b) Connect the connector.
I32421
13. INSTALL DISCHARGE HOSE SUB–ASSY
(a) Remove the attached vinyl tape from the hose.
(b) Sufficiently apply compressor oil to the new O–ring and
fit surface of the compressor and magnetic clutch.
Compressor oil: ND–OIL8 or equivalent
(c) Install a O–ring to the discharge hose sub–assy.
(d) Install the discharge hose sub–assy to the compressor
and magnetic clutch with the bolt.
Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf)
I32459
2004 COROLLA (RM1037U)
Author: Date: 1607
55–38
HEATER & AIR CONDITIONER – COOLER COMPRESSOR ASSY
14. INSTALL COOLER REFRIGERANT SUCTION HOSE
NO.1
(a) Remove the attached vinyl tape from the hose.
(b) Sufficiently apply compressor oil to the new O–ring and
fit surface of the compressor and magnetic clutch.
Compressor oil: ND–OIL8 or equivalent
(c) Install a O–ring to the cooler refrigerant suction hose No.
1.
(d) Install the cooler refrigerant suction hose No. 1 to the
compressor and magnetic clutch with the bolt.
Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf)
I32458
15. CHARGE REFRIGERANT (See page 55–11)
SST 07110–58060 (07117–58060, 07117–58070, 07117–58080, 07117–58090, 07117–78050,
07117–88060, 07117–88070, 07117–88080), 07117–48130, 07117–48140
Specified amount: 490 30 g (17.28 1.06 oz.)
16. WARM UP ENGINE
17. INSPECT LEAKAGE OF REFRIGERANT (See page 55–11)
2004 COROLLA (RM1037U)
Author: Date: 1608
