service LEXUS SC400 1991 Service User Guide

R±12 AIR CONDITIONER SYSTEM RETROFIT ± AC001±98 April 3, 1998
Page 3 of 4
A. Refrigerant handling
1. Do not handle refrigerant in an enclosed area or near an open flame.
2. Always wear eye protection.
3. Avoid getting liquid refrigerant in your eyes or on your skin.
4. Never heat a container with an open flame.
5. Keep containers below 104 °F.
6. When heating a refrigerant can with water, keep the valve above water.
7. Never reuse empty service cans.
B. Replacing parts 1. Plug off any open connections to prevent the entry of moisture and dust.
2. Do not remove plugs from Receiver ports until it is ready for installati\
on.
C. Tightening connecting parts
1. Apply a few drops of ND±Oil 8 compressor oil to O±ring fittings be\
fore tightening.
2. Avoid twisting refrigerant piping when installing R134a service fitting a\
dapters.
3. Tighten all fittings to specified torque.
D. Recharging with A/C ªonº
1. Never open the high side valve with the engine running.
2. Never run the A/C system when low on refrigerant as compressor damage ma\
yoccur.
3. Never charge the system with liquid refrigerant with the engine running.\
4. Be careful not to overcharge the system.
NOTE:
Oil removed during R±12 evacuation should not be used with an R134a Syst\
em.
A. Vehicle Inspection:
Ensure the integrity of the A/C system before proceeding with retrofit.
B. Recover R±12 using R±12 recovery/recycling/recharging equipment: Follow Lexus recommended procedure.
C. Install R134a service fitting adapters: 1. Remove valve cores from R±12 service fittings and discard.
2. Clean external threads of the R±12 service fittings.
3. Apply adhesive to threads (Loctite 262 or equivalent), screw on R134a \
adapterfittings, and tighten to 13 ft±lb.
NOTE:
Vehicles with more than 2 service fittings will require the installation \
of additional
adaptors. All service fittings must have R134a adaptors installed.
D. Replace piping and hose O±rings:
1. Disconnect discharge hose from compressor.
2. Remove and discard old O±rings.
3. Lubricate with ND±Oil 8 and install new O±rings.
4. Disconnect discharge hose from condenser.
5. Lubricate and install retrofit O±rings with ND±Oil 8.
6. Reconnect hoses and torque to specification. (Specifications can be fou\
nd in applicable manuals/guides.)
Service
Precautions
Repair
Procedure
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wTighten the O±ring fittings or the bolted type fittings to
the specified torque.
Precautions When Charging Refrigerant
1. DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH
REFRIGERANT IN REFRIGERANT CYCLE
If there is not enough refrigerant in the refrigerant cycle, oil
lubrication will be insufficient and compressor burnout may
occur, so take care to avoid this.
2. DO NOT OPEN HIGH PRESSURE VALVE OF MANIFOLD GAUGE WITH COMPRESSOR OPERATING
If the high pressure valve is opened, refrigerant flows in the
reverse direction and could cause the charging cylinder to
rupture, so open and close the low pressure valve only.
3. BE CAREFUL NOT TO OVERCHARGE WITH REFRIGERANT IN SYSTEM
If refrigerant is overcharged, it causes trouble such as insuffi-
cient cooling, poor fuel economy, engine overheating etc.
Electrical Parts
Before removing and inspecting the electrical parts, set the
ignition switch to the LOCK position and disconnect the neg-
ative (±) terminal cable from the battery.
CAUTION: Work must not be started until after at least 20
seconds or longer from the time the negative (±) terminal
cable is disconnected.
SRS Airbag System
Failure to carry out service operations in the correct se-
quence could cause the airbag system to deploy, possibly
leading to a serious accident.
When removal or installation of the parts and the yellow wire
harness and connector for the airbag is necessary, refer to
the precautionary notices in the AB section before perform-
ing the operation.
±
AIR CONDITIONING SYSTEM General DescriptionAC±5
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Part No.Part NameNote
07110-58011
(07117-58010)
(07117-78011)
(07117-88013)
(07117-88022)
(07117-88040)
07110-58040
07112-66040
07112-76060
07114-82020
07117-48050
Air Conditioner
Service Tool Set
(Refrigerant Drum
Service Valve)
(Refrigerant
Charging Gauge)
(Refrigerant
Charging Hose)
(Refrigerant
Charging Hose)
(Refrigerant
Charging Hose)
(Stop Valve)
Charging Hose Kit.
w/Stop Valve
Magnetic Clutch
Stopper
Magnetic Clutch
Remover
Snap Ring Pliers
Vacuum Pump Assy
Orange Color
If you require a stop valve, please order this kit.
Rated voltage AC220V
Illustration
IllustrationPart No.Part NameNote
09082-00015TOYOTA
Electrical TesterMeasure voltage currant and resistance
Blue Color
Green Color
PREPARATION
SST (SPECIAL SERVICE TOOLS)
±
AIR CONDITIONING SYSTEM PreparationAC±13
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USE OF MANIFOLD GAUGE SET
INSTALLATION OF MANIFOLD GAUGE
SET
HINT: To prevent releasing refrigerant, use charging hoses
with a stop valve when installing the manifold gauge set to
service valves on the refrigerant line.
1. CONNECT CHARGING HOSES WITH A STOP VALVE TO MANIFOLD GAUGE SET
Tighten the nuts by hand.
CAUTION:
wDo not connect the wrong hoses to the high
pressure and the low pressure sides.
w To prevent loosening the nuts, do not apply
compressor oil to seat of the connection.
2. CLOSE HAND VALVES OF BOTH STOP VALVES
3. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET
4. REMOVE CAPS FROM SERVICE VALVES ON REFRIGERANT LINE
5. CONNECT STOP VALVES TO SERVICE VALVES Tighten the nuts by hand.
CAUTION:
wDo not connect the wrong hoses to the high
pressure and the low pressure sides.
w To prevent loosening the nuts, do not apply
compressor oil to seat of the connection.
6. OPEN HAND VALVES OF BOTH STOP VALVES
REMOVAL OF MANIFOLD GAUGE SET
1. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET
2. CLOSE HAND VALVES OF BOTH STOP VALVES
3. DISCONNECT STOP VALVES FROM SERVICE VALVES ON REFRIGERANT LINE
4. INSTALL CAPS TO SERVICE VAL VES ON REFRIGERANT
LINE
±
AIR CONDITIONING SYSTEM Use of Manifold Gauge SetAC±15
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RECOVERING OF REFRIGERANT IN
REFRIGERANT SYSTEM
When discharging refrigerant from the system as follows, use
a recovery machine to recover the refrigerant.Before replacing parts on the refrigerant line.
When moisture or air gets in the refrigerant line.
When excess refrigerant is charged.
NOTICE:
w When handling the recovery machine, always follow
the directions given in instruction manual.
w After recovery, the amount of compr essor oil
removed must be measured and same am ount
added into the system.
1. INSTALL MANIFOLD GAUGE SET TO SERVICE VALVES See page AC±15
2. RECOVER REFRIGERANT FROM REFRIGERATION
SYSTEM
(a) Connect the center hose to recovery machine.
(b) Operate the recovery machine.
(c) Open both high and low hand valves of manifold gauge set.
3. STOP RECOVERY MACHINE WHEN RECOVERING HAS FINISHED
4. REMOVE MANIFOLD GAUGE SET FROM SERVICE VA LV E S
See page AC±15
AC±16
±
AIR CONDITIONING SYSTEM Recovering of Refrigerant in Refrigerant System
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EVACUATING AIR IN
REFRIGERATION SYSTEM AND
CHARGING WITH REFRIGERANT
HINT: Before charging the system with refrigerant, be sure
carry out a complete evacuation of the system.
1. INSTALL MANIFOLD GAUGE SET TO SERVICE VALVES See page AC±15
2. EVACUATE AIR IN REFRIGERATION SYSTEM (a) Connect the center hose of the manifold gauge set to the vacuum pump.
(b) Open both the high and low hand valves and run the vacuum pump.
HINT: If opening the low pressure hand valve pulls the high
pressure gauge into the vacuum range, there is no blokage
in the system.
(c) After ten minutes or more, check that the low pressure gauge indicates 99.99 kPa (750 mmHg, 29.53 in.Hg) or
more of vacuum.
HINT: If the reading is not 99.99 kPa (750 mmHg, 29.53
in.Hg) or more of vacuum, close both the high and low hand
valves of the manifold gauge set and stop vaccum pump.
Then, check the system for leaks and repair as necessary.
(d) Close both the high and low hand valves and stop the
vacuum pump.
(e) Leave the system in this condition for five minutes or longer and check that there is no change in the gauge
indicator.
3. INSTALL CHARGING CYLINDER NOTICE: When handling the charging cylinder, always
follow the directions given in the instruction manual.
(a) Charge the proper amount of refrigerant in charging cylinder.
(b) Connect the center hose to charging cylinder. NOTICE: Do not open both high and low hand valves of
manifold guage set.
(c) Press on the schrader valve on the side of manifold gauge and expel the air inside of the center hose.
±
AIR CONDITIONING SYSTEM Evacuation Air in Refrigeration
System and Charging with RefrigerantAC±17
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6. CHARGE PARTIALLY REFRIGERATION SYSTEM WITHREFRIGERANT (VAPOR)
HINT: This step is used to charge the system through the low
pressure side with refrigerant in a vapor state.
NOTICE: Do not open the high pressure hand valve when
running the engine.
(a) Run the engine at ideling speed and operate the air
conditioner.
(b) Open the low pressure hand valve. NOTICE: Adjust the hand valve so that the low pressure
gauge does not indicate over limited pressure of charg-
ing cylinder.
(c) Close the low pressure hand valve when the sight glass is free of any bubbles and stop the engine.
NOTICE: Be careful not to overcharge the system with re-
frigerant as it may cause of troubles.
7. REMOVE MANIFOLD GAUGE SET FROM SERVICE VA LV E S
See page AC±15
±
AIR CONDITIONING SYSTEM Evacuation Air in Refrigeration
System and Charging with RefrigerantAC±19
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SERVICE SPECIFICATIONS
SERVICE DATA
Idle speed Magnetic clutch no engaged
Magnetic clutch engaged
Magnetic clutch clearanceApprox. 700 rpm
Approx. 700 rpm
0.5 + 0.15 mm 0.020 + 0.006 in.
TORQUE SPECIFICATIONS
Part tightenedN Vmkgf Vcmft Vlbf
Suction hose X Compressor2525018
Discharge hose X Compressor25250 18
Compressor X EngineBolt 49500 36
Nut 29300 22
Liquid tube X Receiver10 55 7
Liquid tube X Condenser10100 7
Discharge tube X Condenser10100 7
Expansion valve X Evaporator 5.4 55 48 in. Vlbf
Suction tube X A/C Unit10100 7
Liquid tube X A/C Unit10100 7
Equalizer tube X EPR25250 18
Pressure switch X Liquid tube10100 7
±
AIR CONDITIONING SYSTEM Service SpecificationsAC±139
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Check center airbag sensor assembly.
Diagnostic code 14 is not output.(1) Connect connector to center airbag sensor
connector.
(2) Connect connector between center airbag sensor assembly and spiral cable.
(3) Using a service wire, connect D+ and D± on spiral cable side of connector between spiral
cable and steering wheel pad.
(4) Connect negative (±) terminal cable to battery,
and wait at least 2 seconds.
Check squib.
(1) Turn ignition switch ACC or ON, and wait at least 20 seconds.
(2) Using SST, connect terminals Tc and E1 of TDCL.
SST 09843±18020
(3) Check diagnostic code.
(1) Turn ignition switch LOCK.
(2) Disconnect battery negative (±) terminal cable, and wait at least 20 seconds.
(3) Connect steering wheel pad (squib) connector.
(4) Connect negative (±) terminal cable to battery, and wait at least 2 seconds.
Diagnostic code 14 is not output. (1) Turn ignition switch ACC or ON, and wait at least 20 seconds.
(2) UsingSST, connect terminals Tc and E1 of TDCL.
SST 09843±18020
(3) Check diagnostic code. Codes other than code 14 may be output at this
time, but this is not relevant to this check
Codes other than code 14 may be output at this
time, but this is not relevant to this check Replace steering wheel pad.
From the results of the above inspection, the malfunctioning part can no\
w be considered normal.
To make sure this, use the simulation method to check. Replace center airbag sensor assembly.
AB±66±
SRS AIRBAG Troubleshooting
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3
Codes other than code 15 may be output at this
time, but this is not relevant to this check.Replace front airbag sensor.
NG
OK
(1) Turn ignition switch ACC or ON, and wait at least 20
seconds.
(2) Using SST, connect terminals Tc and E
1 of TDCL.
SST 09843±18020
(3) Check diagnostic code.
Check center airbag sensor assmbly.
Check front airbag sensor.
Replace center airbag sensor assembly.NG
OK
Diagnostic code 15 is not output.
(1) Connect connector to center airbag sensor
assembly.
(2) Using a service wire, connect D+ and D± on spiral cable side of connector between spiral
cable and steering wheel pad.
(3) Connect negative (±) terminal cable to battery, and wait at least 2 seconds.
From the results of the above inspection, the malfunctioning part can no\
w be considered normal.
To make sure of this, use the simulation method to check.
4
Disconnect front airbag sensor connector. Measure resistance between each terminal of
front airbag sensor.

Do not touch ohmmeter probes strongly
against terminals of front airbag sensor.

Make sure the front airbag sensor connector
is properly connected.
Terminal Resistance
Below 1 
755
 ±885 
1 M or higher
+S ± +A
+S ± ±S
±S ± ±A
±
SRS AIRBAG TroubleshootingAB±71
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