LEXUS SC400 1991 Service Repair Manual

(b) Using a plastic hammer, tap the rotor off the shaft.NOTICE: Be careful not to damage the pulley when tap-
ping on the rotor.
3. REMOVE STATOR (a) Disconnect the stator lead wire from the compressor housing.
(b) Using a SST, remove the snap ring. SST 07114±84020
(c) Remove the stator.
AC±114
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AIR CONDITIONING SYSTEM Compressor
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ASSEMBLY OF MAGNETIC CLUTCH
1. INSTALL STATOR(a) Install the stator on the compressor.
(b) Using a SST, install the snap ring.SST 07114±84020
NOTICE: The snap ring should be installed so that its
beveled side faces up.
(c) C onnect the stator lead wires to the compressor
housing.
2. INSTALL ROTOR (a) Install the rotor on the compressor shaft.
(b) Using a SST, install the snap ring.SST 07114±84020
NOTICE: The snap ring should be installed so that its
beveled side faces up.
3. INSTALL PRESSURE PLATE (a) Put the shims to the pressure plate.
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AIR CONDITIONING SYSTEM CompressorAC±115
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(b) Using SST and torque wrench, install the shaft bolt.SST 07112±76060
Torque: 14 N Vm (140 kgf Vcm, 10 ft Vlbf)
4. CHECK CLEARANCE MAGNETIC CLUTCH
Check the clearance between the pressure plate and rotor
using thickness gauge.
Standard clearance: 0.5 + 0.15 mm
(0.020 + 0.006 in.)
If the clearance is not within tolerance, change the number
of shims to obtain the standard clearance.
AC±116
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AIR CONDITIONING SYSTEM Compressor
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INSTALLATION OF COMPRESSOR
1. INSTALL COMPRESSOR(a) Install the compressor with the bracket, nut and the three bolts.
Specified torque:
Bolts 51 N Vm (530 kgf Vcm, 38 ft Vlbf)
(b) Install the earth wire harness with the bolts.
(c) Install the wire harness to the clamp.
2. INSTALL DRIVE BELT See step 32 on page EM±177.
3. CONNECT CONNECTOR TO MAGNETIC CLUTCH
4. CONNECT DISCHARGE HOSE AND SUCTION HOSE TO COMPRESSOR
NOTICE: Hoses should be connected immediately after
the caps have been removed.
Specified torque: 25 N Vm (250 kgf Vcm, 18 ft Vlbf)
5. EVACUATE AIR IN REFRIGERATION SYSTEM AND
CHARGE WITH REFRIGERANT
See page AC±17.
Specified amount: 950 + 50 g (33.44 + 1.76 oz)
6. INSPECT FOR LEAKAGE OF REFRIGERANT
Using a gas leak tester, check for leakage of refrigerant.
If there is leakage, check the tightening torque at the joints.
7. INSPECT A/C OPERATION
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AIR CONDITIONING SYSTEM CompressorAC±117
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RECEIVER
ON±VEHICLE INSPECTION
1. REMOVE THE HEADLIGHT ON THE VEHICLE'S LEFTSIDE
See page BE±37
2. INSPECT FITTINGS FOR LEAKAGE Using a gas leak tester, check for leakage.
If there is leakage, check the tightening torque at the joints.
3. INSTALL HEADLIGHT See page BE±37
REMOVAL OF RECEIVER
1. REMOVE THE HEADLIGHT ON THE VEHICLE'S LEFT
SIDE
See page BE±37
2. RECOVER REFRIGERANT IN REFRIGERATION SYSTEM See page AC±16
3. REMOVE TWO LIQUID TUBES FROM RECEIVER Remove the two bolts and both the tubes from the receiver.
4. REMOVE RECEIVER FROM RECEIVER HOLDER Remove the bolt, then remove the receiver from the receiver
holder.
NOTICE: Cap the open fittings immediately to keep mois-
ture out of the system.
AC±118
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AIR CONDITIONING SYSTEM Receiver
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INSTALLATION OF RECEIVER
1. INSTALL RECEIVER IN RECEIVER HOLDERInstall the receiver in the receiver holder with the one bolt.
2. INSTALL TWO LIQUID TUBES ON RECEIVER Install the two liquid tubes on the receiver with the two bolts.
Specified torque: 5.4 N Vm (55 kgf Vcm, 4 ft Vlbf)
NOTICE: Do not remove the caps until the tubes are con-
nected.
3. REPLENISH COMPRESSOR OIL IF RECEIVER HAS BEEN REPLACED
Add 20 cc (0.7 fl.oz.)
Compressor oil: ND OIL 6,
SUNISO NO. 5 GS or equivalent
4. EVACUATE AIR IN REFRIGERATION SYSTEM ANDCHARGE WITH REFRIGERANT
See page AC±17
Specified amount: 950 + 50 g (33.44 + 1.76 oz)
5. INSPECT FOR LEAKAGE OF REFRIGERANT
Using a gas leak tester, check for leakage of refrigerant.
If there is leakage, check the tightening torque at the joints.
6. INSPECT A/C OPERATION
7. INSTALL HEADLIGHT See page BE±37
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AIR CONDITIONING SYSTEM ReceiverAC±119
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CONDENSER
ON±VEHICLE INSPECTION
1. INSPECT CONDENSER FINS FOR BLOCKAGE OR
DAMAGE
If the fins are clogged, wash them with water and dry with
compressed air.
NOTICE: Be careful not to damage the fins.
If the fins are bent, straighten them with a screwdriver or pli-
ers.
2. INSPECT CONDENSER AND FITTINGS FOR LEAKAGE Using a gas leak tester, check for leakage.
If there is leakage, check the tightening torque at the joints.
REMOVAL OF CONDENSER
1. RECOVER REFRIGERANT IN REFRIGERATION SYSTEMSee page AC±16
2. REMOVE BATTERY
3. REMOVE CONDENSER UPPER COVER AND RADIATOR FITTING BOLT
4. REMOVE UNDER COVER AND AIR FLOW COVER
5. REMOVE LIQUID TUBE AND SUCTION TUBE Remove two bolts and both tubes.
NOTICE: Cap open the fittings immediately to keep mois-
ture out of the system.
6. REMOVE CONDENSER Remove two nuts and lean the radiator backward, then re-
move the condenser.
AC±120
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AIR CONDITIONING SYSTEM Condenser
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INSTALLATION OF CONDENSER
1. INSTALL CONDENSERInstall the condenser with two nuts.
2. INSTALL LIQUID TUBE AND DISCHARGE TUBE
Install both tubes with two bolts.
Specified torque:
Discharge tube 10 N Vm (100 kgf Vcm, 7 ft Vlbf)
Liquid tube 10 N Vm (100 kgf Vcm, 7 ft Vlbf)
NOTICE: Don't remove caps until the tube is installed.
3. IF CONDENSER WAS REPLACED, ADD COMPRESSOR OIL TO COMPRESSOR
ADD 40±50 cc (1.4±1.7 ft.oz.)
Compressor oil: ND OIL 6,
SUNISO NO. 5 GS or equivalent
4. EVACUATE AIR IN REFRIGERATION SYSTEM ANDCHARGE WITH REFRIGERANT
See page AC±17
Specified amount: 950 + 50 g (33.44 + 1.76 oz)
5. INSPECT FOR LEAKAGE OF REFRIGERATN
Using a gas leak tester, check for leakage of refrigerant.
6. INSTALL REMOVAL PARTS Install the removal parts in reverse order of removal proce-
dure.
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AIR CONDITIONING SYSTEM CondenserAC±121
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EVAPORATOR
REMOVAL OF EVAPORATOR
1. DISCONNECT NEGATIVE (±) CABLE FROM BATTERY
2. RECOVER REFRIGERANT IN REFRIGERATION SYSTEMSee page AC±16
3. REMOVE ABS ACTUATOR
See page BR±48
4. REMOVE LIQUID TUBE AND SUCTION TUBE Remove two bolts and both tubes.
5. REMOVE EQUALIZER TUBE FROM EPR
Remove the bole and the tube.
NOTICE: Cap the open fittings immediately to keep mois-
ture out of the system.
6. REMOVE UNDER COVER GLOVE BOX AND SIDE AIR DUCT
7. DISCONNECT CONNECTORS AND REMOVE POWER STEERING RELAY BOX COOLING FAN COMPUTER AND
TRC COMPUTER
AC±122
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AIR CONDITIONING SYSTEM Evaporator
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8. PULL FLOOR CARPET DOWN AND REMOVECOMPUTER COVER
9. REMOVE EVAPORATOR COVER AND FOOT AIR DUCT BOLT
10. REMOVE EVAPORATOR (a) Remove six bolts and down the lower case.
(b) Pull and remove the evaporator.
(c) Pull out the evaporator sensor from the evaporator fins.
(d) Remove two bolts using a hexagon wrench and separate the evaporator and expansion valve.
INSPECTION OF EVAPORATOR
1. INSPECT FINS FOR BLOCKAGE
If the fins are clogged, clean them with compressed air.
NOTICE: Never use water to clean the evaporator.
2. INSPECT FITTINGS FOR CRACKS OR SCRATCHES Repair as necessary.
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AIR CONDITIONING SYSTEM EvaporatorAC±123
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