Canada - A/C - Rear Unit A/C, Noise

Bulletin
TSB2056

Issue Date
December 03, 2004

Title
NOISE FROM REAR A/C UNIT

Component
HEATING & AIR CONDITIONING

Models
'04 GX 470

INTRODUCTION:
Some GX 470 owners may experience a crackling/static type sound from the right rear HVAC assembly. This procedure provides a method to improve this condition.

APPLICABLE VEHICLES:
- 2004 model year GX 470 vehicles.






PRODUCTION CHANGE INFORMATION:






PARTS INFORMATION:






WARRANTY INFORMATION:






COMPONENT:

REPAIR PROCEDURES:

1. Verify the Customer Concern.
A. Start the engine.
B. Turn on the front and rear A/C.
a. Face mode.
b. Blower on low.
c. Re-circulate mode.

C. Raise the engine RPM to 1500.
D. Listen for crackling sound from the right rear (may take 5-10 minutes).

If there is a noticeable noise coming from the right rear HVAC system, continue with Step 2 of this procedure.

2. Evacuate Refrigerant HFC-134a (R134a).
Refer to ETAS, 2004 GX 470 Repair Manual, Heater & Air Conditioner: Refrigerant: Replacement (GX470).

3. Remove Interior Trim.
Refer to ETAS, 2004 GX 470 Repair Manual, Heater & Air Conditioner: Cooling (Rear) Unit Assy: Overhaul (GX470).
A. Remove rear no. 2 seat assembly RH.
B. Remove rear door scuff plate RH.
C. Remove rear door opening trim weatherstrip RH.
D. Remove rear floor mat support plate rear.
E. Remove package tray trim panel assembly.
F. Remove quarter inside trim board RH.
G. Remove roof side garnish inner RH.






4. Disconnect the Refrigerant Supply Pipe.
A. Remove the nut and separate the supply pipe from the cooler assembly.
B. Remove the O-ring from the refrigerant supply pipe.

NOTE:
Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign material from entering.

5. Disconnect the Refrigerant Suction Pipe.
A. Remove the nut and separate the refrigerant suction pipe from the cooler assembly.






6. Remove Cooler Air Duct No. 1., Upper
A. Remove the clip and the cooler air duct no. 1.






7. Remove Cooling (Rear) Unit Assembly.
A. Disconnect the connectors.
B. Remove the 3 bolts and the cooling (rear) unit assembly.






8. Remove Cooler Air Duct No. 1., Lower
A. Release the clamp and remove the 3 screws and the cooler air duct no.1.






9. Remove Cooler Unit Case.
A. Remove the 6 screws and the 2 brackets.






B. Release the 4 claw fittings and the clamp, and remove the 7 screws and the 2 cooler unit cases.






10. Remove Air Conditioning Tube Assembly.
A. Using a hexagon wrench 4.0 mm (0.15 in.), remove the 2 hexagon bolts and the air conditioning tube assembly.
B. Remove the 2 O-rings from the air conditioning tube assembly.






11. Remove Rear Cooling Unit Expansion Valve.
A. Remove the rear cooling unit expansion valve.

12. Replace the Expansion Valve.
A. Sufficiently apply compressor oil to 2 new O-rings and the surface of the expansion valve.
- Compressor oil: ND-OIL 8 or equivalent

B. Install the 2 O-rings to the evaporator sub-assembly.

13. Replace the Air Conditioner Tube Assembly.
A. Sufficiently apply compressor oil to 2 new O-rings and the surface of the tube assembly.
- Compressor oil: ND-OIL 8 or equivalent

B. Install the 2 O-rings to the tube assembly.

14. Reassemble and install the cooler unit case.






15. Install Cooling (Rear) Unit Assembly.
A. Install the cooling (rear) unit assembly with the 3 bolts.

NOTE:
Tighten the bolts in the order shown in the illustration to install the cooling (rear) unit assembly.

16. Install the Refrigerant Supply Pipe.
A. Remove the attached vinyl tape.
B. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the rear cooler and accessory assembly.
- Compressor oil: ND-OIL 8 or equivalent

C. Install a new O-ring on the refrigerant supply pipe.
D. Connect the refrigerant supply pipe to the cooler assembly.
E. Install the retaining nut.

Torque: 9.8 N-m (100 kgf-cm, 87 in.-lbf)

17. Install the Refrigerant Suction Pipe.
A. Remove vinyl tape.
B. Install a new O-ring on the suction pipe.
C. Connect the refrigerant suction pipe to the cooler assembly.
D. Install the retaining nut.

Torque: 9.8 N-m (100 kgf-cm, 87 in.-lbf)

18. Charge refrigerant
HFC-134a (R134a).






Standard: Dual A/C: 700 +/- 30 g (24.68 +/- 1.06 oz.)

19. Warm Up Engine.
20. Inspect for Refrigerant Leakage.
21. Reinstall the Removed Side Panels, Seat, and Scuff Plate.

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.