Technical Service BULLETIN

Transcription

1 Technical Service BULLETIN Title: Models: Sequoia TSB UPDATE NOTICE: The information contained in this TSB supercedes TSBs AC and AC The previous TSBs, AC and AC001 02, should be discarded. AC HEATING & AIR CONDITIONING Introduction To improve the durability and integrity of repairs on model year Sequoia vehicles with rear A/C, a new suction tube and in line filter system is now available. Please follow the procedures in this bulletin if the compressor is being replaced because of a noise concern and/or has seized. Applicable Vehicles model year Sequoia vehicles produced BEFORE the Production Change Effective VINs shown below. Production Change Information MODEL PRODUCTION CHANGE PRODUCTION CHANGE EFFECTIVE VIN Suction Tube 5TD**##A#2S Sequoia Additional Oil 5TD**##A#2S Compressor 5TD**##A#3S Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 AC2001 R & R Compressor w/clutch & Receiver C070 Combo A R & R Front Expansion Valve C020 Combo B R & R Compressor Filter / Liquid Line w/filter / C070 Rear Expansion Valve Combo C Suction Tube No. 1 Replacement C030 Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle s in-service date. * Warranty application is limited to correction of a problem based upon a customer s specific complaint. Toyota Supports ASE Certification Page 1 of 11

2 Parts Information PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME C C091 Suction Tube No C C100 Compressor Assembly Receiver Tank C070 Same Filter Kit C020 Front Expansion Valve C Rear Expansion Valve Same Snap Ring Snap Ring 1 QTY Required SSTs PART NUMBER SPECIAL SERVICE TOOLS (SSTs) QTY * A/C Line Disconnect Kit 1 (or equivalent) Low Side A/C Line Disconnect Tool (included in A/C Line Disconnect Kit) High Side A/C Line Disconnect Tool (included in A/C Line Disconnect Kit) (or equivalent) (or equivalent) (or equivalent) * Essential SST. Magnetic Clutch Stopper 1 Pressure Plate Remover 1 Snap Ring Pliers 1 Additional SSTs may be ordered by calling SPX/OTC at Compressor and Magnetic Clutch On Vehicle Inspection A. Start the engine. B. Inspect the compressor for a metallic rattle sound. a. Check if there is a metallic rattle sound from the compressor when the A/C switch is on. b. If a metallic rattle sound is heard, replace the compressor assembly. C. Inspect magnetic clutch condition. a. Check the magnetic clutch for signs of overheating. b. If there are signs of overheating replace the magnetic clutch. Page 2 of 11

3 2. Suction Tube Replacement A. Recover the refrigerant from the refrigeration system. Figure 1 Suction Tube B. Remove the suction tube. a. Using the SST, or equivalent low side A/C line disconnect tool, release the 3 piping clamps. Figure 2 Suction Tube SST ( ) b. Remove the suction tube from the engine compartment. The suction tube will not be installed until step 11 of this bulletin. 3. Compressor Removal A. Please follow the instructions for compressor removal in the Technical Information System (TIS), 2003 Sequoia Manual, Air Conditioning: Compressor and Magnetic Clutch. The compressor will not be re installed until Step 14 of this bulletin. Page 3 of 11

4 4. Receiver Tank Replacement A. Please follow the instructions for receiver removal in the Technical Information System (TIS), 2003 Sequoia Manual, Air Conditioning: Receiver: Removal. Figure 3 (P/N ) (P/N ) B. Please follow the instructions for receiver installation in the Technical Information System (TIS), 2003 Sequoia Manual, Air Conditioning: Receiver: Installation. 5. Front Line Cleaning A. At the front of the vehicle, remove the discharge line from the condenser. Figure 4 Suction Hose B. At the front of the vehicle, remove the suction hose. C. Use high pressure shop air to blow through the lines until no debris is present. If solvents are used as a cleaning agent, use only the solvents designed for A/C system cleaning. D. Re install the discharge hose. a. Install new s and lubricate with ND Oil 8 (or equivalent) Discharge Hose b. Torque the retaining nut to 5.4 N m (55 kgf cm, 48 in. lbf) E. Re install the suction hose. Page 4 of 11

5 6. Rear Expansion Valve Removal A. Remove rear seat outer belt floor anchors. B. Remove back door scuff plate. C. Remove rear door scuff plate RH. D. Remove upper back door garnish. E. Remove rear window side garnish RH. F. Remove rear quarter trim panel RH. G. Remove quarter pillar garnish RH. H. Remove the 4 screws and 2 brackets shown in Figure 5. Figure 5 I. From the underside of the vehicle, remove the supply line retaining nut and pull the line down away from the connection point. J. From the underside of the vehicle, remove the return line retaining nut and pull the line down away from the vehicle. K. Remove the expansion valve and associated tubing from the vehicle. Figure 6 Supply Line Retaining Nut Return Line Retaining Nut Page 5 of 11

6 7. Rear Line Cleaning A. At the front of the vehicle remove the liquid line B shown in Figure 7. Figure 7 Liquid Line B The liquid line being removed will not be reused. a. Using the SST, or equivalent A/C line disconnect tool, release the 2 piping clamps at the bulkhead end of liquid line B. Piping Clamps b. Remove the liquid line B retaining nut and associated isolation clamps. Liquid Line B Retaining Nut c. Remove liquid line B from the engine compartment. B. Use shop high pressure air to blow any particles from the rear lines. Blow from front to rear until no debris is present. (See Figure 8.) IMPORTANT: The direction of R134 movement in the liquid line is from front to rear. For maximum particle removal blow from the front to the rear only. Figure 8 Blow High Pressure Air Into These Points If solvents are used as a cleaning agent, use only the solvents designed for A/C system cleaning. Page 6 of 11

7 8. Rear Expansion Valve Inspection A. Remove the rear expansion valve packing material. Figure 9 Inlet Retaining Nut The packing material will not be reused. B. Remove the expansion valve inlet retaining nut. (See Figure 9.) C. Remove the expansion valve outlet retaining nut. D. Pull the expansion valve away from the tubes, being careful not to damage the sensing tube. E. Inspect the expansion valve inlet and outlet for metal debris. If no metal debris is found, proceed to step 9 for reinstallation of the expansion valve. Outlet Retaining Nut If metal debris is found: Remove and replace the front and rear expansion valves. Page 7 of 11

8 9. Installation of Rear Expansion Valve Before installation, lubricate the threads and O rings with ND Oil 8 (or equivalent) to ensure proper seal. Figure 10 Inlet Retaining Nut A. Install the expansion valve onto the evaporator connection tube but do not fully tighten the retaining nuts. B. Carefully place the sensing bulb on the flat spot of the return line and use the original retaining clip to secure the bulb in place. C. Torque the inlet and outlet retaining nuts to specification. Outlet Retaining Nut Torque: Inlet Retaining Nut: 13 N m (135 kgf cm, 10 in. lbf) Outlet Retaining Nut: 22 N m (235 kgf cm, 16 in. lbf) D. Wrap the expansion valve with the packing material provided in the field fix kit. E. Wrap the sensing bulb and suction tube with the original packing or an equivalent packing material. Figure 11 (P/N ) (P/N ) (P/N ) (P/N ) F. Install the expansion valve and tubing onto the evaporator. At time of installation, use new O rings lubricated with ND Oil 8 (or equivalent). Figure 12 Torque: 5.4 N m (55 kgf cm, 48 in. lbf) Page 8 of 11

9 G. From the underside of the vehicle, install the supply line retaining nut. H. From the underside of the vehicle, install the return line retaining nut. Figure 13 (P/N ) Supply Line Retaining Nut (P/N ) At time of installation, use new O rings lubricated with ND Oil 8 (or equivalent). Torque: 5.4 N m (55 kgf cm, 48 in. lbf) Return Line Retaining Nut 10. Front Expansion Valve Please follow the instructions for front expansion valve removal and replacement in the Technical Information System (TIS), 2003 Sequoia Manual, Air Conditioning: Cooling Unit. 11. Installation of Liquid Line B A. Ensure that the line being installed is the new part with the in line filter as shown in Figure 14. Figure 14 New Liquid Line B With In Line Filter At the time of installation lubricate the O rings with ND Oil 8 (or equivalent). B. Install the 2 piping clamps at the bulkhead end of liquid line B. C. Install the liquid line retaining nut. In Line Filter Lubricate the threads with ND Oil 8 (or equivalent) to ensure proper torque. Torque: 5.4 N m (55 kgf cm, 48 in. lbf) Page 9 of 11

10 12. Installation of Suction Tube A. Install the suction tube into the vehicle. Lubricate the O rings with ND Oil 8 (or equivalent) to ensure proper seal. B. Install the 3 piping clamps. 13. Prepare New Compressor for Installation a. Using the 2 nuts supplied in the field fix kit, double nut the studs as shown in Figure 15. b. Jam the nuts by turning the bottom nut counterclockwise and the top nut clockwise. c. Turn the bottom nut counterclockwise to remove the stud. Figure 15 Double Nut Studs The studs will not be reused. d. Repeat steps a c for the other stud. e. Install the filter plate (Figure 16) using the 2 small bolts supplied in the field fix kit. Figure 16 Filter Plate Lubricate the new gasket with ND Oil 8 (or equivalent) before installation to ensure a proper seal. Torque: 10 N m (100 kgf cm, 7 ft lbf) The compressor will not be installed until Step 14 of this bulletin. Page 10 of 11

11 14. Compressor Installation A. Install suction and Figure 17 discharge lines. a. Install new O rings and lubricate with ND Oil 8 (P/N ) (or equivalent). b. Insert the lines into the filter plate. Use the bolts supplied in the field fix kit to retain the lines. The bolts are not the same length. Use the short bolt to retain the suction hose. (P/N ) Lubricate the threads with ND Oil 8 (or equivalent) to ensure proper torque. Torque: 10 N m (100 kgf cm, 7 ft lbf) c. Please follow the instructions for compressor installation in the Technical Information System (TIS), 2003 Sequoia Manual, Air Conditioning: Compressor and Magnetic Clutch. 15. System Oil Requirements After the A/C system has been opened and evacuated, the correct quantity of lubricating oil must be restored to the system. Following a replacement of a large component, the repair manual specifies the exact amount of oil to be recharged in addition to the amount removed during recovery. A new or remanufactured compressor will come filled with 200 cc of oil. A. The Sequoia dual A/C system oil requirement has been increased from 200 cc to 300 cc. (Refer to Production Change Information on page 1.) B. Each time a compressor and receiver/dryer are removed from a system, approximately 100 cc of oil is removed with them, leaving the remaining oil in the system. Keep this in mind when adding a new compressor with 200 cc of oil. 16. Charge System with Refrigerant A. Evacuate air from the system. B. Charge system with refrigerant to specified amount and inspect for leakage. Specified amount (dual A/C): 1,050 +/ 50 g ( / 1.76 oz.) Page 11 of 11