FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
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Home >> Lexus >> 2009 >> LS 460 AWD V8-4.6L (1UR-FSE) >> Repair and Diagnosis >> Heating and Air Conditioning >> Compressor HVAC >> Service and Repair >> Installation

Installation








AIR CONDITIONING: COMPRESSOR AND MAGNETIC CLUTCH: INSTALLATION

INSTALLATION

1. ADJUST COMPRESSOR OIL
(a) When replacing the compressor and magnetic clutch with a new one, gradually discharge the refrigerant gas from the service valve, and drain the following amount of oil from the new compressor and magnetic clutch before installation.
Standard:
(Oil capacity inside the new compressor and magnetic clutch: 130 + 15 cc (4.6 + 0.51 fl.oz.) ) - (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed from the new compressor when replacing)
NOTICE:
- When checking the compressor oil level, observe the A/C system's precautions.
- If a new compressor and magnetic clutch is installed without removing some oil remaining in the pipes of the vehicle, the oil amount will be too large. This prevents heat exchange in the refrigerant cycle and causes refrigerant failure.
- If the volume of oil remaining in the removed compressor and magnetic clutch is too small, check for oil leakage.
- Be sure to use ND-OIL 8 or equivalent for compressor oil.





2. INSTALL COOLER COMPRESSOR ASSEMBLY
(a) Install the cooler compressor with the 2 stud bolts
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Install the 2 bolts and 2 nuts.
Torque: 24.5 Nm (250 kgf-cm, 18 ft-lbf)
NOTE:
Tighten the nuts and bolts in the order shown in the illustration to install the cooler compressor.

(c) Connect the connector.





3. CONNECT DISCHARGE HOSE SUB-ASSEMBLY
(a) Remove the attached vinyl tape from the hose.
(b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor.
Compressor oil:
ND-OIL 8 or equivalent
(c) Install the O-ring to the cooler refrigerant discharge hose.
(d) Install the cooler refrigerant discharge hose to the cooler compressor with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 7 ft-lbf)





4. CONNECT SUCTION HOSE SUB-ASSEMBLY
(a) Remove the attached vinyl tape from the hose.
(b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor.
Compressor oil:
ND-OIL 8 or equivalent
(c) Install the O-ring to the cooler refrigerant suction hose.
(d) Install the cooler refrigerant suction hose to the cooler compressor with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 7 ft-lbf)
5. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY (for Bank 1) Installation
6. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Installation
7. INSTALL POWER STEERING LINK ASSEMBLY
(a) W/ VGRS:
Install the power steering link Installation.
(b) W/O VGRS:
Install the power steering link Installation.
8. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
(a) W/ VGRS:
Install the No. 2 steering intermediate shaft Installation.
(b) W/O VGRS:
Install the No. 2 steering intermediate shaft Installation.
9. INSTALL STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY
(a) W/ VGRS:
Install the steering sliding with shaft yoke Installation.
(b) W/O VGRS:
Install the steering sliding with shaft yoke Installation.
10. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH Installation
11. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH Installation
12. INSTALL FRONT STABILIZER BAR Installation
13. INSTALL REAR ENGINE UNDER COVER RH
14. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY Installation
15. INSTALL FRONT EXHAUST PIPE ASSEMBLY
(a) Install the front exhaust pipe Installation.
16. INSTALL ENGINE ROOM ECU OUTLET DUCT





(a) Install the engine room outlet duct.
17. INSTALL AIR CLEANER ASSEMBLY RH Installation
18. INSTALL AIR CLEANER CAP SUB-ASSEMBLY RH
19. INSTALL AIR CLEANER ASSEMBLY LH Installation
20. INSTALL AIR CLEANER CAP SUB-ASSEMBLY LH
21. INSTALL FAN AND GENERATOR V BELT Installation
22. INSTALL INTAKE AIR CONNECTOR PIPE
23. INSTALL RADIATOR RESERVOIR ASSEMBLY
24. INSTALL NO. 1 AIR CLEANER INLET
25. INSTALL FRONT SUSPENSION CROSSMEMBER LOWER





(a) Install the frame rail with the 6 bolts and 4 nuts.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
26. INSTALL REAR FRAME SIDE RAIL
(a) Install the frame rail with the 6 bolts and 4 nuts.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
27. INSTALL FRONT BUMPER COVER
(a) Install the front bumper cover Installation.
28. INSTALL RADIATOR SUPPORT OPENING COVER
29. INSPECT FOR EXHAUST GAS LEAK
30. INSTALL FRONT WHEEL
31. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
32. CHECK AND ADJUST FRONT WHEEL ALIGNMENT
(a) Check and adjust the front wheel alignment Front Wheel Alignment.
33. CHECK SHIFT LEVER POSITION
34. INSTALL FRONT SUSPENSION MEMBER PROTECTOR LOWER





(a) Install the suspension member protector with the 8 bolts.
35. INSTALL NO. 2 ENGINE UNDER COVER





(a) Install the under cover with the 8 bolts.
36. INSTALL NO. 1 ENGINE UNDER COVER Service and Repair
37. INSTALL V-BANK COVER SUB-ASSEMBLY
38. INSTALL ENGINE ROOM SIDE COVER RH





(a) Install the side cover with the 4 clips.
39. INSTALL ENGINE ROOM SIDE COVER LH





(a) Install the side cover with the 4 clips.
40. INSTALL AIR CLEANER INLET COVER SUB-ASSEMBLY
41. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
42. INSTALL COWL TOP VENTILATOR LOUVER RH Installation
43. ADD COMPRESSOR OIL Service and Repair
44. CHARGE REFRIGERANT Service and Repair
45. WARM UP ENGINE Service and Repair
46. CHECK FOR LEAKAGE OF REFRIGERANT Service and Repair
47. PERFORM INITIALIZATION
(a) Perform initialization Repair Instruction - Initialization.
NOTE:
Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
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