Repair Procedure
1. Compressor and Magnetic Clutch On-Vehicle InspectionA. 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.
2. Suction Tube Replacement
A. Recover the refrigerant from the refrigeration system.
B. Remove the suction tube.
a. Using the SST, or equivalent low side A/C line disconnect tool, release the 3 piping clamps.
^ SST 09870-00005-01 (09870-00015-01)
b. Remove the suction tube from the engine compartment.
NOTE:
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 Repair Manual, Air Conditioning: Compressor and Magnetic Clutch.
NOTE:
The compressor will not be re-installed until Step 14 of this bulletin.
4. Receiver Tank Replacement
A. Please follow the instructions for receiver removal in the Technical Information System (TIS), 2003 Sequoia Repair Manual, Air Conditioning: Receiver: Removal.
B. Please follow the instructions for receiver installation in the Technical Information System (TIS), 2003 Sequoia Repair Manual Air Conditioning Receiver: Installation.
5. Front Line Cleaning
A. At the front of the vehicle, remove the discharge line from the condenser.
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.
NOTE:
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 0-Rings and lubricate with ND Oil 8 (or equivalent).
b. Torque the retaining nut to 5.4 N.m (55 kgf.cm, 48 in..lbf)
E. Re-install the suction hose.
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.
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.
7. Rear Line Cleaning
A. At the front of the vehicle remove the liquid line B shown in Figure 7.
NOTE:
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.
b. Remove the liquid line B retaining nut and associated isolation clamps.
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.
NOTE:
If solvents are used as a cleaning agent, use only the solvents designed for A/C system cleaning.
8. Rear Expansion Valve Inspection
A. Remove the rear expansion valve packing material.
NOTE:
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.
> If metal debris is found:
Remove and replace the front and rear expansion valves.
9. Installation of Rear Expansion Valve
HINT:
Before installation, lubricate the threads and 0-rings with ND Oil 8 (or equivalent) to ensure proper seal.
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.
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.
F. Install the expansion valve and tubing onto the evaporator.
HINT:
At time of installation, use new 0-rings lubricated with ND Oil 8 (or equivalent).
Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf)
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.
HINT:
At time of installation, use new 0-rings lubricated with ND Oil 8 (or equivalent).
Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf)
10. Front Expansion Valve
Please follow the instructions for front expansion valve removal and replacement in the Technical Information System (TIS), 2003 Sequoia Repair 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.
HINT:
At the time of installation lubricate the 0-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.
HINT:
Lubricate the threads with ND Oil 8 (or equivalent) to ensure proper torque.
Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf)
12. Installation of Suction Tube
A. Install the suction tube into the vehicle.
HINT:
Lubricate the 0-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.
NOTE:
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.
HINT:
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)
NOTE:
The compressor will not be installed until Step 14 of this bulletin.
14. Compressor Installation
A. Install suction and discharge lines.
a. Install new 0-rings and lubricate with ND Oil 8 (or equivalent).
b. Insert the lines into the filter plate. Use the bolts supplied in the field fix kit to retain the lines.
NOTE:
The bolts are not the same length. Use the short bolt to retain the suction hose.
HINT:
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 Repair 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.)
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 (37.03+/- 1.76 oz.)