LEMON Manuals: Even more car manuals for everyone
Home >> Lexus >> 2021 >> LC 500 2D Convertible >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> Heating / Air Conditioning System - Service Information (Convertible) (2 Of 2) >> Compressor >> Installation [07/2020 - 05/2023] >> Procedure

Installation [07/2020 - 05/2023]: 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.
      • Do not race the engine before replacing the compressor assembly with pulley.
      • 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.
      GTY964425Courtesy 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.

      GTY963623Courtesy 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.

      HINT: 

      The drain bolt (seal washer) can be reused.

      GTY964425Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Drain the following amount of compressor oil from the oil port of the new compressor assembly with pulley as shown in the illustration.
      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 a 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)).
      GTY963623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Oil Port *b Turn Clockwise

      Standard

      (The amount of oil in a new compressor assembly with pulley: 70 (+15) cc (2.37 (+0.51) 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.

    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, temporarily install the compressor assembly with pulley with the 2 stud bolts.

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

      GTY963199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the compressor assembly with pulley with the 2 nuts and 2 bolts.

      Nut, Bolt 

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

      NOTE:

      Tighten the 2 nuts and 2 bolts in the order shown in the illustration.

      Fig 1: Compressor Assembly And Bolts With Tightening Sequence
      GTY964287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    3. Attach the clamp and connect the engine wire.
      GTY963686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Connector
    4. Connect the connector.
    5. Connect the wiring harness clamp bracket with the bolt.

      Torque: 17.5 N.m (178 kgf/cm, 13 ft.lbf) 

  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) 

      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)
      GTY964152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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)
      GTY964151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. 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) 

      GTY964155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL SUCTION HOSE SUB-ASSEMBLY 
    1. Remove the vinyl tape from the suction hose sub-assembly and suction tube sub-assembly B.
    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction tube sub-assembly B.

      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 suction tube sub-assembly B 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 suction tube sub-assembly B.
      • Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)
      GTY964153Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FAN AND GENERATOR V BELT 

    Refer to PROCEDURE - Step 1

  8. INSTALL INTAKE AIR CONNECTOR PIPE 
    1. Align the cutout of the intake air connector pipe with the protrusion of the intake air sound creator and connect the intake air connector pipe as shown in the illustration.
      NOTE:

      Insert the intake air connector pipe until it hits the stopper.

      GTY959935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion *b Cutout
      *c Stopper *d View A
      *e Positioning Stopper - -
      Bolt Intake Air Connector Pipe Hose Clamp
    2. Tighten the intake air connector pipe hose clamp as shown in the illustration.
      NOTE:

      Install the intake air connector pipe hose clamp so that it contacts the intake air connector pipe positioning stopper.

      Torque: 4.0 N.m (41 kgf/cm, 35 in.lbf) 

    3. Install the intake air connector pipe with the bolt.

      Torque: 5.0 N.m (51 kgf/cm, 44 in.lbf) 

  9. INSTALL AIR (WITH ELEMENT) CLEANER ASSEMBLY WITH AIR CLEANER INLET 
    NOTE:

    Check that the air cleaner support is properly installed to the specified position on the air cleaner support bracket and upper radiator support.

    1. Install the air (with element) cleaner assembly with air cleaner inlet to the air cleaner support.
      GTY959918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Air Cleaner Support - -
      *a Clamp - -
    2. Attach the clamp as shown in the illustration.

      Installation Position

      Part Length
      A 310 mm (1.02 ft.)
      B 176 to 186 mm (6.93 to 7.32 in.)
      C 60.5 to 68.5 mm (2.38 to 2.70 in.)
    3. for LH side of vehicle:
      1. Connect the connector.
        GTY964225Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Attach the clamp.
    4. for RH side of vehicle:
      1. Connect the 2 connectors.
        GTY964226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Attach the clamp.
      3. Connect the vacuum hose to the connector as shown in the illustration.

        Installation Position

        Part Length
        A 2 mm (0.0787 in.) or less
        GTY963690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Connector
      4. Install the vacuum hose to the guide.
  10. INSTALL AIR CLEANER HOSE ASSEMBLY 

    Refer to PROCEDURE - Step 2

  11. CONNECT NO. 2 PCV HOSE 

    Refer to PROCEDURE - Step 3

  12. CONNECT NO. 3 PCV HOSE 

    Refer to PROCEDURE - Step 4

  13. INSTALL RADIATOR SUPPORT TO CROSSMEMBER BRACE SUB-ASSEMBLY RH 
    1. Install the radiator support to crossmember brace sub-assembly RH with the bolt (A) and bolt (B).

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

      GTY963854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt (A)
      Bolt (B)
  14. INSTALL RADIATOR SUPPORT TO CROSSMEMBER BRACE SUB-ASSEMBLY LH 
    1. Install the radiator support to crossmember brace sub-assembly LH with the bolt (A) and bolt (B).

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

      GTY964423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt (A)
      Bolt (B)
  15. CONNECT FRONT STABILIZER BAR 

    Refer to PROCEDURE - Step 1

  16. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY 

    Refer to PROCEDURE - Step 143

  17. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 5

  18. WARM UP ENGINE 

    Refer to PROCEDURE - Step 6

  19. INSPECT FOR REFRIGERANT LEAK 

    Refer to PROCEDURE - Step 7

  20. INSTALL LOWER RADIATOR AIR DEFLECTOR 

    Refer to PROCEDURE - Step 8

  21. INSTALL RADIATOR SUPPORT TO FRAME SEAL LH 

    Refer to PROCEDURE - Step 9

  22. INSTALL RADIATOR SUPPORT TO FRAME SEAL RH 

    Refer to PROCEDURE - Step 10

  23. INSTALL V-BANK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 147

scientia non olet · About LEMON Manuals