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Canada - A/C - A/C Compressor, Knocking Noise

Bulletin
TSB2014

Issue Date
June 23, 2004

Title
A/C COMPRESSOR "KNOCKING" SOUND

Component
HEATING & AIR CONDITIONING

Models
'04 LS 430

On some 2004 model year LS 430 vehicles, the A/C compressor may make a "knocking" sound under certain conditions. An updated A/C compressor has been developed to improve the condition.

APPLICABLE VEHICLES:
- 2004 model year LS 430 vehicles produced BEFORE the Production Change Effective VINs shown below.






PRODUCTION CHANGE INFORMATION:






PARTS INFORMATION:






WARRANTY INFORMATION:

REPLACEMENT PROCEDURE:

1. Disconnect Negative Terminal Cable from Battery.

NOTE:
Record customer's audio presets before disconnecting battery.

2. Evacuate Refrigerant HFC-134A (R134A).(Refer to ETAS, 2004 model year LS 430 Repair Manual: Section: Heater & Air Conditioner; Subsection: Refrigerant.)

3. Remove Air Cleaner Inlet No. 1. (Refer to ETAS, 2004 model year LS 430 Repair Manual: Section: Engine Mechanical; Subsection: Partial Engine Assy.)

4. Remove Fan and Generator V-belt. (Refer to ETAS, 2004 model year LS 430 Repair Manual: Section: Engine Mechanical: Subsection: Drive Belt.)

5. Remove Engine Under Cover No. 1.






6. Disconnect Cooler Refrigerant Discharge Hose No. 1.
a. Remove the nut and disconnect the cooler refrigerant discharge hose No. 1.
b. Remove the O-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.
b. Remove the O-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 Compressor Mounting Bracket No. 1.
a. Remove the bolt, nut and compressor mounting bracket No. 1.






9. Remove Compressor Assembly.
a. Disconnect the connector.
b. Remove the 2 bolts and compressor assembly.

10. Adjust Compressor Oil.
a. When replacing the compressor with a new one, after gradually removing the refrigerant gas from the service valve, drain the following amount of oil from the new compressor before installation.

Standard:
(Oil capacity inside the new compressor: 130 + 15 cc (4.4 + 0.5 fl. oz)) - (Remaining oil amount in the removed compressor) = (Oil amount to be removed from the new compressor when replacing)

NOTE:
When checking the compressor oil level, observe the precautions on the air conditioning radiator assembly removal/installation.
Because compressor oil remains in the pipes of the vehicle, if a new compressor is installed without removing some oil inside, the oil amount becomes too much, preventing heat exchange in the refrigerant cycle and causing refrigerant failure.
If the remaining oil in the removed compressor is too small in volume, check for oil leakage. Be sure to use ND-OIL 8 (or equivalent) for compressor oil.






11. Temporary Tighten Compressor Assembly.
a. Temporarily tighten the compressor assembly with the 2 bolts.
b. Connect the connector.






12. Install Compressor Mounting Bracket No. 1.
a. Install the compressor mounting bracket No. 1 with the bolt and nut.

Torque:
Bolt: 49 N-m (500 kgf-cm, 36 ft-lbf)
Nut: 30 N-m (306 kgf-cm, 22 ft-lbf)






13. Tighten Compressor Assembly.
a. Fully tighten the compressor assembly with the 2 bolts.

Torque: 49 N-m (500 kgf-cm, 36 ft-lbf)






14. Install Cooler Refrigerant Suction Hose No. 1.
a. Remove the attached vinyl tape from the hose.
b. Sufficiently apply compressor oil to the new O-ring and fitting surface of the compressor.

Compressor oil: ND-OIL 8 (or equivalent)

c. Install an O-ring to the cooler refrigerant suction hose No. 1.
d. Install the cooler refrigerant suction hose No. 1 to the compressor with the bolt.

Torque: 9.8 N-m (100 kgf-cm, 7 ft-lbf)






15. Install Cooler Refrigerant Discharge Hose No. 1.
a. Remove the attached vinyl tape from the hose.
b. Sufficiently apply compressor oil to the new O-ring and fitting surface of the compressor.

Compressor oil: ND-OIL 8 (or equivalent)

c. Install an O-ring to the cooler refrigerant discharge hose No. 1.
d. Install the cooler refrigerant discharge hose No. 1 to the compressor with the nut.

Torque: 9.8 N-m (100 kgf-cm, 7 ft-lbf)

16. Install Fan and Generator V-belt. (Refer to ETAS, 2004 model year LS 430 Repair Manual: Section: Engine Mechanical; Subsection: Drive Belt.)
17. Install Air Cleaner Inlet No. 1. (Refer to ETAS, 2004 model year LS 430 Repair Manual: Section: Engine Mechanical; Subsection: Partial Engine Assy.)
18. Connect Negative Terminal Cable to Battery.

NOTE:
After reconnecting the negative battery terminal:
- Initialize the driver's power seat. (Refer to ETAS, 2004 model year LS 430 Repair Manual: Section: Introduction; Subsection: Repair Instruction; Initialization.)
- Reset customer's audio presets.

19. Charge Refrigerant. (Refer to ETAS, 2004 model year LS 430 Repair Manual: Section: Heater & Air Conditioner; Subsection: Refrigerant.)
20. Warm Up Engine.
21. Inspect for Refrigerant Leakage. (Refer to ETAS, 2004 model year LS 430 Repair Manual: Section: Heater & Air Conditioner; Subsection: Refrigerant.)

NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.
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