A/C - Moaning Sound Heard at 1,100 to 1,400 RPM's
HEATING & AIR CONDITIONINGAC001-06
REVISED
April 19, 2006
^ July 13, 2007: The hint in step 19 has been updated.
^ May 18, 2006: A previous part number has been added to the Parts Information table for the coolant refrigerant discharge hose No. 1.
Previous versions of this TSIB should be discarded.
The information contained in this TSIB supercedes TSIB No. AC002-04 and AC004-04. TSIB No. AC002-04 and AC004-04 are now obsolete and should be discarded.
Introduction
Some 2004 - 2006 RX 330 owners may experience a moan noise heard at 1100 rpm to 1400 rpm with the NC ON. Production changes to the discharge hose and clutch hub have been implemented to prevent this problem. This service bulletin provides a procedure to improve this condition.
Applicable Vehicles
^ 2004 - 2006 model year RX 330 vehicles.
Parts Information
Warranty Information
Applicable Warranty*:
This repair is covered under the Lexus Comprehensive Warranty. This warranty is in effect for 48 months or 50,000 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.
Required Tools & Material
Required Equipment
Required SSTs
Repair Procedure
1. Verify the customer concern.
A. Start the engine.
B. Turn the A/C ON.
C. Hold the engine rpm between 1100-1400.
D. Turn the A/C OFF.
If there is a noticeable moan sound with the A/C ON and no sound when the A/C is OFF, continue with this repair procedure.
2. Remove the engine side cover. Remove the 4 clips and then remove the engine side cover.
3. Evacuate the refrigerant HFC-134a (R-134a).
Equipment: Robinair R-134a
Refrigerant Recovery/Recycling
Machine (P/N R0B34200)
4. Remove the engine under cover assembly.
Remove the 5 clips, 4 bolts, and 2 screws, and then remove the engine under cover.
5. Remove V belt No. 1 (from the cooler compressor to crankshaft pulley).
A. Loosen bolt C.
B. Loosen bolt A.
C. Loosen bolt B and remove the V belt No. 1 (from the cooler compressor to crankshaft pulley).
6. Disconnect cooler refrigerant discharge hose No. 1.
A. Remove the nut and disconnect the cooler refrigerant discharge hose No. 1 from the compressor and magnetic clutch.
B. Remove the 0-ring from the cooler refrigerant discharge hose No. 1.
NOTE:
Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
7. Disconnect cooler refrigerant suction hose No. 1.
A. Remove the bolt and disconnect the cooler refrigerant suction hose No.1 from the compressor and magnetic clutch.
B. Remove the 0-ring from the cooler refrigerant suction hose No. 1.
NOTE:
Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
8. Remove the compressor and magnetic clutch.
A. Remove the bolt and wire harness bracket.
B. Disconnect the connector and clamp.
C. Remove the 2 bolts, nut, and the cooler compressor bracket.
D. Remove the 3 bolts and the compressor and magnetic clutch.
9. Remove the magnetic clutch assembly.
NOTE:
Do NOT change the combination of the magnetic clutch washers used before disassembly.
A. Remove the 2 bolts and bracket.
B. Place the compressor and magnetic clutch in a vise.
NOTE:
Do NOT get the bracket and harness caught in the vise.
C. Using the SST, hold the magnetic clutch hub.
SSTO7112-76060
D. Remove the bolt, magnetic clutch hub, and magnetic clutch washer.
There is NO set number of magnetic clutch washers since they are used for adjusting.
10. Install the magnetic clutch washers and NEW magnetic clutch hub.
Using the SST, hold the magnetic clutch hub and torque the bolt.
^ SSTO7112-76060
Torque: 18 N.m
(183 kgf.cm, 13 ft.lbf)
Make sure that there is NO foreign matter or oil on the compressor shaft, bolt, and clutch hub.
11. Inspect the magnetic clutch clearance.
A. Set the dial gauge to the magnetic clutch hub.
B. Connect the positive (+) battery lead to terminal 3 of the magnetic clutch connector and the negative lead to the ground wire. Turn ON and OFF the magnetic clutch and measure the clearance.
Standard clearance: 0.35 to 0.60 mm (0.013 to 0.023 in.)
If the measured value is NOT within the standard range, remove the magnetic clutch hub and adjust it with magnetic clutch washers.
NOTE:
Adjustment should be performed with 3 or less magnetic clutch washers.
C. Remove the compressor and the magnetic clutch from the vise.
D. Install the bracket with 2 bolts.
12. Remove the cooler refrigerant discharge hose No. 1.
A. Remove the bolt and disconnect the cooler refrigerant discharge hose from the condenser assembly.
B. Remove the bolt from the piping clamp and remove the cooler discharge hose.
NOTE:
The next step is for 2004 model year vehicles only. If the vehicle is a 2005 - 2006 model year, go to step 14.
13. Replace the cooler bracket.
A. Remove the bolt and then remove the cooler bracket.
B. Install the NEW cooler bracket and hand start the bolt.
C. Torque the bolt.
Torque: 9.8 N.m (100.0 kgf.cm, 85 in.lbf)
14. Install the NEW cooler refrigerant discharge hose No. 1.
A. Sufficiently apply compressor oil to the 0-ring and fitting surface of the condenser.
B. Connect the cooler refrigerant discharge hose to the condenser assembly and hand start the bolt.
C. Torque the bolt.
Torque: 9.8 N.m (100.0 kgf.cm, 85 in.lbf)
D. Place the piping clamp on the isolator stud and hand start the nut.
E. Torque the nut.
Torque: 9.8 N.m (100.0 kgf.cm, 85 in.lbf)
15. Install the compressor and magnetic clutch.
A. Hand start the 3 bolts.
B. Fully tighten the compressor and magnetic clutch with bolt A and bolt B.
Torque: 25 N.m (250 kgf.cm, 18 in.lbf)
C. Install the cooler compressor bracket with the 2 bolts and nut.
Bolt C Torque: 25 N.m (250 kgf.cm, 18 in.lbf)
Nut D Torque: 25 N.m (250 kgf.cm, 18 in.lbf)
Bolt E Torque: 18 N.m (184 kgf.cm, 13 in.lbf)
D. Tighten the compressor and magnetic clutch with bolt F.
Torque: 25 N.m (250 kgf.cm, 18 in.lbf)
E. Connect the connector and clamp on the cooler compressor bracket.
F. Install the wire harness bracket with the bolt.
16. Install cooler refrigerant suction hose No.1.
A. Remove the attached vinyl tape from the hose.
B. Sufficiently apply compressor oil to the NEW 0-ring and fitting surface of the compressor and magnetic clutch.
Compressor Oil: ND-01L8 or equivalent
C. Install the 0-ring to cooler refrigerant suction hose No.1.
D. Install cooler refrigerant suction hose No.1 to the compressor and magnetic clutch with the bolt.
Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
17. Install cooler refrigerant discharge hose No.1.
A. Sufficiently apply compressor oil to the NEW 0-ring and fitting surface of the compressor and magnetic clutch.
Compressor Oil: ND-01L8 or equivalent
B. Install cooler refrigerant discharge hose No. 1 to the compressor and magnetic clutch. Hand start the nut.
Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
18. Temporarily Install V belt No.1 (from the cooler compressor to crankshaft pulley).
19. Adjust V belt No.1 (from the cooler compressor to crankshaft pulley).
Apply drive belt tension by turning bolt B.
Drive Belt Tension:
New Belt: 170 +/- 10 lbf Used Belt: 125 +/- 10 lbf
HINT:
^ "New belt" refers to a belt that has been used on a running engine at idling for 5 minutes or less.
^ "Used belt" refers to a belt that has been used on a running engine at idling for 5 minutes or more.
NOTE:
Check that the drive belt fits properly in the ribbed grooves.
20. Fully tighten V belt No.1 (from the cooler compressor to crankshaft pulley).
A. Tighten bolt A.
Torque: 18 N.m (183 kgf.cm, 13 ft.lbf)
B. Tighten bolt C.
Torque: 58 N.m (591 kgf.cm, 43 ft.lbf)
21. Recharge the refrigerant HFC-134a (R-134a).
Equipment: Robinair R-134a Refrigerant Recovery/Recycling Machine (P/N R0B34200)
Specified amount: 600 +/- 50 g (21.15 +/- 1.76 oz)
22. Warm up engine.
23. Inspect for any refrigerant leakage.
24. Verify the repair.
A. Start the engine.
B. Turn the A/C ON.
C. Hold the engine rpm between 1100-1400 and confirm NO moan sound.
D. Turn the A/C OFF.
25. Install the engine under cover assembly.
A. Install the engine under cover.
B. Install the 5 clips, 4 bolts, and 2 screws.
26. Install the engine side cover.
A. Install the engine side cover.
B. Install the 4 clips.