LEMON Manuals: Even more car manuals for everyone
Home >> Lexus >> 2019 >> LS 500 Base, RWD >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> Heating / Air Conditioning System - Service Information (3 Of 3) >> COMPRESSOR (for AWD) >> Installation [11/2021 - ] >> Procedure

Installation [11/2021 - ]: Procedure

  1. ADJUST COMPRESSOR OIL 
    1. When replacing the compressor assembly with pulley with a new one, gradually discharge the inert gas (helium) from the service valve, and drain the following amount of oil before installation.
      NOTE:
      • If a new compressor assembly with pulley is installed without removing the same amount of compressor oil as is remaining in the pipes, the amount of compressor oil will be excessive. This prevents heat exchange in the refrigerant cycle and will cause the air conditioning system to malfunction.
      • A certain amount of compressor oil remains in the compressor assembly with pulley during circulation and the compressor may be damaged if the amount of compressor oil is more/less than this amount. Therefore, make sure to adjust the amount of compressor oil correctly.
      • If the amount of compressor oil remaining in the removed compressor assembly with pulley is excessively low, check for compressor oil leaks.
      • Make sure to use ND-OIL 12 or equivalent compressor oil.
    2. Remove the drain bolt (seal washer) from the removed compressor assembly with pulley.
      GTY1087377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Drain the compressor oil from the oil port of the removed compressor assembly with pulley as shown in the illustration.
      NOTE:

      Make sure to drain the compressor oil from the oil port.

      GTY1087602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Oil Port *b Turn Clockwise
    4. Remove the drain bolt (seal washer) from the new compressor assembly with pulley.
      GTY1087377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      The drain bolt (seal washer) can be reused.

    5. Drain the following amount of compressor oil from the oil port of the new compressor assembly with pulley as shown in the illustration.

      Standard

      (The amount of oil in a new compressor assembly with pulley: 100 to 115 cc (3.38 to 3.89 fl.oz)) - (The amount of oil in the removed compressor assembly with pulley) = The amount of oil to be removed from the new compressor assembly with pulley.

      NOTE:
      • Make sure to drain the compressor oil from the oil port.
      • Make sure to add the compressor oil from the oil port, not from the discharge or intake port.
      • If a tool is used to add compressor oil to the new compressor assembly with pulley, make sure that it is free of foreign matter.
      • If the amount of compressor oil remaining in the removed compressor assembly with pulley cannot be estimated because the compressor was damaged and oil was discharged due to a frontal collision, etc., install the new compressor assembly with pulley without removing any oil. If the cooler condenser assembly is also replaced, do not add the specified amount of compressor oil for cooler condenser assembly replacement (40 cc (1.35 fl.oz)).
      GTY1087602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Oil Port *b Turn Clockwise
    6. Install the drain bolt (seal washer) to the new compressor assembly with pulley.

      Torque: 30 N.m (306 kgf/cm, 22 ft.lbf) 

      NOTE:

      Make sure that there is no damage or foreign matter on the seal washer edge.

  2. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY 
    1. Using an E8 "TORX" socket wrench, install the 2 stud bolts.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

      GTY775442Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the compressor assembly with pulley with the nut and 2 bolts.
      GTY1088111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    3. Temporarily install the oil filter bracket with the nut.
      GTY1087374Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten the 2 nuts and 2 bolts in the order shown in the illustration.
      GTY1088117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut

      Nut, Bolt 

      Torque: 24.5 N.m (250 kgf/cm, 18 ft.lbf) 

    5. Connect the connector.
      GTY1087373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. CONNECT SUCTION HOSE SUB-ASSEMBLY 
    1. Remove the vinyl tape from the suction hose sub-assembly and connecting part of the compressor assembly with pulley.
    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor assembly with pulley.

      Compressor Oil

      ND-OIL 12 or equivalent

    3. Install the O-ring to the suction hose sub-assembly.
      NOTE:

      Keep the O-ring and O-ring fitting surface free of foreign matter.

    4. Connect the suction hose sub-assembly to the compressor assembly with pulley with the bolt.

      Torque: 9.8 N.m (100 kgf/cm, 87 in.lbf) 

      GTY1087372Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not apply excessive force to the suction hose sub-assembly.
      • Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)
  4. CONNECT DISCHARGE HOSE SUB-ASSEMBLY 
    1. Remove the vinyl tape from the discharge hose sub-assembly and connecting part of the compressor assembly with pulley.
    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor assembly with pulley.

      Compressor Oil

      ND-OIL 12 or equivalent

    3. Install the O-ring to the discharge hose sub-assembly.
      NOTE:

      Keep the O-ring and O-ring fitting surface free of foreign matter.

    4. Connect the discharge hose sub-assembly to the compressor assembly with pulley with the bolt.

      Torque: 9.8 N.m (100 kgf/cm, 87 in.lbf) 

      NOTE:
      • Do not apply excessive force to the discharge hose sub-assembly.
      • Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)
      GTY1088049Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY (for Bank 2) 

    Refer to PROCEDURE - Step 1

  6. INSTALL NO. 2 AIR TUBE ASSEMBLY 

    Refer to PROCEDURE - Step 3

  7. INSTALL AIR CLEANER SUPPORT BRACKET ASSEMBLY 
    1. Install the air cleaner support bracket assembly with the 2 bolts.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

      GTY775444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL NO. 13 CONNECTOR HOLDER 
    1. Attach the clamp to install the No. 13 connector holder to the air cleaner support bracket assembly.
      GTY776948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Clamp
      *b Guide
    2. Connect the connector.
  9. INSTALL SUCTION HOSE SUB-ASSEMBLY 
    1. Remove the vinyl tape from the suction hose sub-assembly and air conditioning tube and accessory assembly.
    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioning tube and accessory assembly.

      Compressor Oil

      ND-OIL 12 or equivalent

    3. Install the O-ring to the suction hose sub-assembly.
      NOTE:

      Keep the O-ring and O-ring fitting surface free of foreign matter.

    4. Connect the suction hose sub-assembly to the air conditioning tube and accessory assembly with the nut.

      Torque: 9.8 N.m (100 kgf/cm, 87 in.lbf) 

      NOTE:
      • Do not apply excessive force to the suction hose sub-assembly and air conditioning tube and accessory assembly.
      • Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)
      GTY775422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL WATER PUMP BRACKET SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  11. CONNECT INLET INTERCOOLER COOLING WATER HOSE 

    Refer to PROCEDURE - Step 3

  12. INSTALL INTERCOOLER RESERVE TANK ASSEMBLY 

    Refer to PROCEDURE - Step 33

  13. INSTALL AIR CLEANER WITH ELEMENT ASSEMBLY RH 

    Refer to PROCEDURE - Step 128 [10/2020 - 10/2023] , or refer to PROCEDURE - Step 128 [10/2023 - ]

  14. INSTALL AIR CLEANER WITH ELEMENT ASSEMBLY LH 

    Refer to PROCEDURE - Step 127 [10/2020 - 10/2023] , or refer to PROCEDURE - Step 127 [10/2023 - ]

  15. INSTALL RADIATOR SUPPORT TO CROSSMEMBER BRACE SUB-ASSEMBLY RH 
    1. Install the radiator support to crossmember brace sub-assembly RH with the 2 bolts.
      GTY834649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 49 N.m (500 kgf/cm, 36 ft.lbf) 

  16. INSTALL RADIATOR SUPPORT TO CROSSMEMBER BRACE SUB-ASSEMBLY LH 
    1. Install the radiator support to crossmember brace sub-assembly LH with the 2 bolts.
      GTY837321Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 49 N.m (500 kgf/cm, 36 ft.lbf) 

  17. INSTALL NUT 
    1. Using a 12 mm union nut wrench and SST, install the nut.
      GTY833137Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length - -
      • SST: 09961-00950 

      Specified tightening torque 

      Torque: 24.5 N.m (250 kgf/cm, 18 ft.lbf) 

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Refer to PRECAUTION [10/2020 - 10/2023] , or refer to PRECAUTION [10/2023 - ]

      • When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + SST (fulcrum length of 150 mm (5.906 in.)) + torque wrench (fulcrum length of 162 mm (6.378 in.)): 12 N.m (122 kgf/cm, 9 ft.lbf)
  18. INSTALL FAN AND GENERATOR V BELT 

    Refer to PROCEDURE - Step 1

  19. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 5

  20. ADD ENGINE COOLANT 

    Refer to PROCEDURE - Step 9

  21. ADD COOLANT (for Intercooler) 

    Refer to PROCEDURE - Step 5

  22. INSPECT FOR COOLANT LEAK 

    Refer to PROCEDURE - Step 3

  23. INSPECT FOR COOLANT LEAK (for Intercooler) 

    Refer to PROCEDURE - Step 1

  24. WARM UP ENGINE 

    Refer to PROCEDURE - Step 6

  25. INSPECT FOR REFRIGERANT LEAK 

    Refer to PROCEDURE - Step 7

  26. INSTALL ENGINE UNDER COVER BRACKET RH 

    Refer to PROCEDURE - Step 6

  27. INSTALL STRUT BAR BRACKET SUPPORT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 180 [10/2020 - 10/2023] , or refer to PROCEDURE - Step 179 [10/2023 - ]

  28. INSTALL FRONT SUSPENSION MEMBER BRACE 

    Refer to PROCEDURE - Step 181 [10/2020 - 10/2023] , or refer to PROCEDURE - Step 180 [10/2023 - ]

  29. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY 

    Refer to PROCEDURE - Step 184 [10/2020 - 10/2023] , or refer to PROCEDURE - Step 183 [10/2023 - ]

  30. INSTALL LOWER RADIATOR AIR DEFLECTOR 

    Refer to PROCEDURE - Step 8

  31. INSTALL UPPER RADIATOR SUPPORT SEAL 

    Refer to PROCEDURE - Step 9

  32. INSTALL RADIATOR COVER PLATE 

    Refer to PROCEDURE - Step 10

  33. INSTALL V-BANK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 193 [10/2020 - 10/2023] , or refer to PROCEDURE - Step 192 [10/2023 - ]

scientia non olet · About LEMON Manuals