Toyota 88410-34040
Clutch Assembly

The first step to replace HVAC system refrigerant lines requires that the refrigeration system discharges its current refrigerant. The next step involves replacing the damaged tube or hose after immediately sealing open system openings to block system entry by moisture and dirt. Use a torque wrench to tighten the connections following the specified value but stay below this mark. The refrigeration system requires evacuation followed by refrigerant charging with 500 plus or minus 30 g (17.64 plus or minus 1.06 oz.). The operation of the air conditioning system must be checked after the team uses a gas leak detector to inspect for refrigerant leakage.

The service or repair process for the compressor clutch starts by letting the engine idle while the air conditioning operates for 10 minutes before stopping the engine and taking out the negative (-) battery cable. The refrigeration system must be discharged of its refrigerant through suitable procedures while the person needs to remove engine under cover and detach suction and discharge hoses by unscrewing both bolts. This step requires immediate fitting of caps to defend system components from moisture and dirt intrusion. Begin by removing the drive belt before breaking loose the PS pump set bolt and nut and disconnecting the compressor by removing its 4 bolts and connector. The compressor installation requires 4 bolts attachment at 25 Nm torque (250 kg.cm, 18 ft.lb) followed by connector reconnection. After lubricating two new O-rings with compressor oil you should install the discharge and suction hoses using their respective 2 bolts while maintaining a torque of 10 Nm (100 kg.cm, 7 ft.lb). The drive belt installation and under cover/engine and PS pump set bolt install requires 43 Nm torque (440 kg.cm, 32 ft.lb). After reconnecting the negative terminal cable to the battery personnel should remove all air from the system and perform a 600 plus or minus 50 g (21.16 plus or minus 1.76 oz.) refrigerant charge. A gas leak detector should be used to identify possible refrigerant leaks which requires a torque check on all joints and A/C operation examination after searching for leaks.

Inspect for refrigerant leakage using a gas leak detector, and if any leakage is found, check the tightening torque at the joints.

Disconnect the connector, remove the 4 bolts and nut, then remove the cooler bracket before taking out the compressor.

For the 2RZ-FE and 3RZ-FE engines, remove 4 bolts; for the 5VZ-FE engine, remove 5 bolts.

Take care not to damage the pulley.

Install the Special Service Tool on the pressure plate and remove it with the socket wrench, then take out the shims from the pressure plate.

Install and check the drive belt, then reinstall the engine under cover. For 5VZ-FE engine models, install the power steering pump set bolt and nut, torquing to 43 N.m (440 kgf.cm, 32 ft.lbf).

Disconnect the stator lead wire from the compressor housing, use Special Service Tool: 95994-10020 to remove the snap ring, and then take out the stator.

Use 530 ± 50 g (18.69 ± 1.76 oz.) for the Double Cab and 600 ± 50 g (21.16 ± 1.76 oz.) for all other configurations.