COMPONENTS REMOVAL

COMPONENTS

Fig 1: Identifying Compressor And Magnetic Clutch Components (Exploded View)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVAL

YMMS: Sep 22, 2021Engine: 4.7L Eng License:VIN: Odometer:

2005 Toyota Sequoia SR5

1. RUN ENGINE AT IDLE SPEED WITH A/C ON FOR APPROX. 10 MINUTES

2. STOP ENGINE

3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

4. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM

5. DISCONNECT DISCHARGE AND SUCTION HOSESRemove the 2 nuts and disconnect both hoses.

NOTE: Cap the openings fitting immediately to keep

moisture or dirt out of the system.

6. REMOVE DRIVE BELT (See REMOVAL)Fig 2: Disconnecting Discharge And Suction Hoses


7. REMOVE COMPRESSOR

a. Disconnect the connector.

b. Remove the 3 bolts and nut.

c. Remove the cooler bracket.

d. Remove the compressor.

Fig 3: Removing Compressor


DISASSEMBLY

1. REMOVE PRESSURE PLATE

a. Using SST and a socket wrench, remove the shaft bolt.SST 07112-76060Torque: 18 N.m (184 kgf.cm, 12.3 ft.lbf)

Fig 4: Removing Pressure Plate Shaft Bolt


b. Install SST on the pressure plate.SST 07112-66040

Fig 5: Installing SST On Pressure Plate


c. Using SST and a socket wrench, remove the pressure plate.SST 07112-66040, 07112-76060,

Fig 6: Removing Pressure Plate


d. Remove the shims from the pressure plate.

Fig 7: Removing Pressure Plate Shims


2. REMOVE ROTOR

a. Using SST, remove the snap ring.SST 95994-10020

Fig 8: Removing Snap Ring


NOTE: The snap ring should be installed so that its beveled

side faces up.

Fig 9: Installing Snap Ring


b. Using a plastic hammer, remove the rotor from the shaft.

NOTE: Be careful not to damage the pulley when tapping on

the rotor.

Fig 10: Removing Rotor From Shaft


3. REMOVE STATOR

a. Disconnect the stator lead wire from the compressor housing.

Fig 11: Disconnecting Stator Lead Wire From Compressor Housing


b. Using SST, remove the snap ring.SST 95994-10020

Fig 12: Removing Snap Ring


NOTE: The snap ring should be installed so that its beveled

side faces up.

Fig 13: Installing Snap Ring


c. Remove the stator.

Fig 14: Removing Stator


Compressor Circuit

CIRCUIT DESCRIPTION

The integration control and panel outputs the magnetic clutch ON signal from terminal AC1 to the ECM. Whenthe ECM receives this signal, it sends a signal from terminal ACT and switches the A/C magnetic clutch relayON. This turns the A/C magnetic clutch on.

WIRING DIAGRAM

Fig 15: Compressor Circuit Wiring Diagram


INSPECTION PROCEDURE

1. Read value of hand-held tester.PREPARATION:

a. Connect the hand-held tester to the DLC3.

b. Turn the ignition switch ON and push the hand-held tester main SW ON.CHECK:Select the item below in the DATA LIST, and read the displays on the hand-held tester.ENGINE AND ECT / ALL:

Fig 16: Engine And ECT / All Data List Table


HINT:Check with the engine running.OK:The display is as specified in the normal condition.

1. NG: Go to step 8.

2. OK: Go to next step.

2. Read value of hand-held tester.PREPARATION:


b. Turn the ignition switch ON and push the hand-held tester main SW ON.CHECK:Select the item below in the DATA LIST, and read the displays on the hand-held tester.ENGINE AND ECT / ALL:Fig 17: Tester Connection/Condition/Specified Condition Table


HINT:Check with the engine running.OK:The display is as specified in the normal condition.

1. NG: Replace ECM (See ENGINE CONTROL MODULE (ECM) ).


3. Perform active test by hand-held tester.PREPARATION:


b. Turn the ignition switch ON and push the hand-held tester main SW ON.CHECK:Select the item below in the DATA LIST, and read the displays on the hand-held tester.AIR CONDITIONING:DATA LIST AIR CONDITIONING

Item Test Details / Display (Range) Diagnostic Note

A/C MAG CLUTCH Magnet clutch relay / OFF, ON Operating sound can be heard

HINT:Check with the engine running.OK:The operation sound of the MG CLT relay can be heard.

1. NG: Go to step 5.


4. Check harness and connector between integration control and panel (ACT terminal) and ECM (ACTterminal) (See HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE ).

1. NG: Repair or replace harness or connector.

2. OK: Proceed to next circuit inspection shown in problem symptoms table (See PROBLEMSYMPTOMS TABLE).

5. Check magnetic clutch relay.PREPARATION:Remove the magnetic clutch relay from the engine room J/B.CHECK:Measure the resistance according to the value(s) in the table below.OK:TESTER CONNECTION AND SPECIFIED CONDITION

Testerconnection Condition Specified condition

3 - 5 Always 10 k Ω or higher

3 - 5 Voltage is applied betweenterminals 1 and 2

Below 1 Ω (Battery voltage is applied betweenterminals 1 and 2)

Fig 18: Checking Magnetic Clutch Relay


1. NG: Replace magnetic clutch relay.


6. Check A/C magnetic clutch.PREPARATION:Disconnect the magnetic clutch connector.CHECK:Connect the positive (+) battery lead to the magnetic clutch connector terminal 3.OK:Magnetic clutch is energized.

Fig 19: Connecting Positive (+) Battery Lead To Magnetic Clutch Connector Terminal 3


1. NG: Replace A/C magnetic clutch.


7. Check harness and connector between integration control and panel (MGC terminal) and bodyground (See HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE ).


2. OK: Replace integration control and panel.

8. Check harness and connector between integration control and panel (AC1 terminal) and ECM (AC1terminal) (See HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE ).



9. Check voltage between terminal AC1 of integration control and panel connector and body ground.PREPARATION:

a. Disconnect the connector from the ECM.

b. Remove the integration control and panel with the connectors still connected.

c. Start the engine and push the AUTO switch.CHECK:Measure the voltage between terminal AC1 of the integration control and panel connector and bodyground when the magnetic clutch is turned ON and OFF by the A/C switch.OK:TESTER CONNECTION AND SPECIFIED CONDITION

Switch operation Tester connection Specified condition

ON AC1 - Body ground 1.3 to 2.6V

OFF AC1 - Body ground 3.7 to 4.5V

Fig 20: Identifying Terminal AC1 On Integration Control And Panel Connector


1. NG: Replace integration control and panel.

2. OK: Replace ECM (See ENGINE CONTROL MODULE (ECM) ).

DTC 22: Compressor Lock Sensor Circuit

CIRCUIT DESCRIPTION

This sensor sends 1 pulse per engine revolution to the integration control and panel.If the compressor speed divided by the engine speed is smaller than a predetermined value, the integrationcontrol and panel turns the compressor OFF. The indicator flashes at about 1 second intervals.

Fig 21: Diagnostic Trouble Code 22 Table


WIRING DIAGRAM

Fig 22: DTC 22 Compressor Lock Sensor Circuit Wiring Diagram


INSPECTION PROCEDURE

1. Check compressor.PREPARATION:

a. Check and adjust compressor drive belt tension (See DRIVE BELT ).CHECK:

a. Check that the compressor does not lock when starting the engine and turning the A/C switch on.OK: Cooler compressor assy does not lock during operation

HINT:If the compressor drive belt slips when the A/C switch is on, the magnet clutch seems to be locked. If thecondition continues for more than 3 seconds, the A/C amplifier turns off the magnet clutch for compressordrive belt protection.

1. NG: Replace compressor.


2. Check compressor lock sensor.PREPARATION:Disconnect the compressor connector.CHECK:Measure the resistance between terminals 1 and 2 of the compressor lock sensor connector.OK:Resistance: 65 to 125 Ω at 20° C (68 ° F)Fig 23: Measuring Resistance Between Terminals 1 And 2 On Compressor Lock Sensor Connector


Reference: Inspection using oscilloscopeDuring cranking or idling, measure the voltage between terminals LOCK and SG-TAM of the integrationcontrol and panel.HINT:The correct waveform appears as shown in the illustration on the left.

Fig 24: Identifying Lock In Signal Waveform


1. NG: Replace compressor.


3. Check harness and connector between compressor lock sensor and integration control and panel(See HOW TO PROCEED WITH TROUBLESHOOTING ).


2. OK: Replace integration control and panel.

ON-VEHICLE INSPECTION

1. SET MANIFOLD GAUGE SET (See MANIFOLD GAUGE SET)

2. START ENGINE

3. INSPECT COMPRESSOR FOR METALLIC SOUNDCheck if a metallic sound can be heard from the compressor when the A/C switch is on.If a metallic sound cannot be heard, replace the compressor assembly.

4. INSPECT REFRIGERANT PRESSURE (See ON-VEHICLE INSPECTION)

5. STOP ENGINE

6. INSPECT VISUALLY FOR LEAKAGE OF REFRIGERANT FROM SAFETY SEALUsing a gas leak detector, check for leakage of refrigerant. If there is any leakage, replace the compressorassembly.

7. REMOVE MANIFOLD GAUGE SET (See SET OFF)

8. CHECK FOR LEAKAGE OF GREASE FROM CLUTCH BEARING

9. CHECK FOR SIGNS OF OIL ON PRESSURE PLATEIf necessary, repair or replace.

10. INSPECT MAGNETIC CLUTCH BEARING FOR NOISE

a. Start the engine.

b. Check if abnormal noise is heard from near the compressor when the A/C switch is OFF.If abnormal noise is being emitted, replace the magnetic clutch.

11. INSPECT MAGNETIC CLUTCH OPERATION


b. Connect the positive (+) lead from the battery to terminal 3 and the negative (-) lead to body ground.

c. Check that the magnetic clutch is energized.If operation is not as specified, replace the magnetic clutch.

Fig 25: Inspecting Magnetic Clutch Operation


12. INSPECT COMPRESSOR LOCK SENSOR RESISTANCE


b. Measure the resistance between terminals 1 and 2.Standard resistance:165 to 205 Ω at 20° C (68° F)If resistance is not as specified, replace the compressor.

Fig 26: Inspecting Compressor Lock Sensor Resistance


REASSEMBLY

Reassembly is in the reverse order of disassembly (See DISASSEMBLY).AFTER REASSEMBLY, CHECK MAGNETIC CLUTCH CLEARANCE

a. Set the dial indicator to the pressure plate of the magnetic clutch.

b. Connect the magnetic clutch lead wire to the positive (+) terminal of the battery.

c. Check the clearance between the pressure plate and rotor when connecting the negative (-) terminal to thebattery.

Standard clearance:0.35 to 0.50 mm (0.014 to 0.024 in.)If the clearance is not within the standard range, adjust the clearance using shims to obtain the standardclearance.

Standard thickness:

0.1 mm (0.004 in.)

0.3 mm (0.012 in.)

0.5 mm (0.020in.)

Fig 27: Checking Magnetic Clutch Clearance


INSTALLATION

1. INSTALL COMPRESSOR

a. Install the compressor with the cooler bracket with the 3 bolts and nut.Torque:Bolt: 47 Nm (480 kgf.cm, 35 in.lbf)Nut: 25 Nm (255 kgf.cm, 18 in.lbf)

b. Connect the connector.

2. CONNECT DISCHARGE AND SUCTION HOSESConnect both hoses with the 2 nuts.

1. Torque: 10 N.m (100 kgf.cm, 7 in.lbf)

NOTE: Hoses should be connected immediately after the

caps have been removed.

HINT:Lubricate 2 new O-rings with compressor oil and install them to the hoses.

3. INSTALL AND CHECK DRIVE BELT (See INSTALLATION,DRIVE BELT)

4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

5. EVACUATE AIR FROM REFRIGERATION SYSTEM

6. CHARGE SYSTEM WITH REFRIGERANTSpecified amount:Single A/C: 750 +/- 50g (26.45 +/- 1.76 oz.)Dual A/C: 1050 +/- 50g (37.03 +/- 1.76 oz.)

7. INSPECT FOR LEAKAGE OF REFRIGERANTUsing a gas leak detector, check for leakage of refrigerant.If there is leakage, check the tightening torque at the joints.

8. PERFORM INITIALIZATION (See INITIALIZATION )Some systems need initialization when disconnecting the cable from the negative battery terminal.

Reprinted Under License from Toyota Motor Sales, U.S.A., Inc., License Agreement TMS1002

COMPONENTS REMOVAL

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