Air Conditioning Radiator Assembly
OVERHAUL
HINT: The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
2. DISCONNECT COOLER REFRIGERANT SUCTION PIPE NO.1
a. Remove the bolt, slide the plate and disconnect the cooler refrigerant suction pipe.
b. Remove the O-ring.
NOTE:
- Do not use any tools in this procedure.
- Keep the system free from moisture or foreign matter.
HINT: Cover the opening of the connectors immediately after disconnecting.
3. DISCONNECT COOLER REFRIGERANT LIQUID PIPE A
HINT: Use the liquid pipe disconnection procedures for the suction pipe No.1.
4. DISCONNECT HEATER WATER OUTLET HOSE A
a. Move the clip and then disconnect the outlet hose from the heater unit.
5. DISCONNECT HEATER WATER INLET HOSE A
a. Slide the clip, and then disconnect the inlet hose.
6. SET RADIO RECEIVER ASSEMBLY TO SHIPMENT MODE
a. Take out all CDs.
NOTE: If CD(s) cannot be taken out, do not attempt to take it out forcibly. Send the unit to a repair shop.
b. While simultaneously pressing the "SEEK UP" and "DISC" switches, turn the ignition switch to ACC.
HINT:
- The CD indicator lamp blinks during mode setting and it remains lit after the setting is completed.
- When the mode setting is completed, "SHIPMENT" appears on the display.
c. Turn the ignition switch OFF.
HINT: Disconnecting the cable from the battery.
7. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
8. INSPECT CENTER FRONT WHEEL
9. REMOVE STEERING WHEEL COVER LOWER NO.2
10. REMOVE SWITCH & VOLUME CASE
11. REMOVE STEERING PAD SWITCH MODULATOR
12. REMOVE HORN BUTTON ASSEMBLY
13. REMOVE STEERING WHEEL ASSEMBLY
14. REMOVE DOOR SCUFF PLATE ASSEMBLY RH
15. REMOVE DOOR SCUFF PLATE ASSEMBLY LH
16. REMOVE FRONT DOOR OPENING TRIM COVER RH
17. REMOVE FRONT DOOR OPENING TRIM COVER LH
18. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY NO.1
19. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY
20. REMOVE STEERING COLUMN COVER LOWER
21. REMOVE STEERING COLUMN COVER UPPER
22. REMOVE TURN SIGNAL SWITCH ASSEMBLY
23. REMOVE COMBINATION METER ASSEMBLY
24. REMOVE CONSOLE UPPER PANEL GARNISH REAR
25. REMOVE CONSOLE PANEL SUB-ASSEMBLY UPPER
26. REMOVE AIR CONDITIONER CONTROL ASSEMBLY
27. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY LOWER CENTER
28. CONFIRM RADIO RECEIVER ASSEMBLY SHIPMENT MODE SETTING
29. w/o LEXUS navigation system:
REMOVE INSTRUMENT PANEL SAFETY PAD GARNISH SUB-ASSEMBLY
30. w/ LEXUS navigation system:
REMOVE INSTRUMENT PANEL SAFETY PAD GARNISH SUB-ASSEMBLY
31. w/ LEXUS navigation system:
REMOVE INSTRUMENT PANEL GARNISH SUB-ASSEMBLY NO.2
32. w/ LEXUS navigation system:
REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY CENTER
33. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY NO.2
34. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY
35. REMOVE CONSOLE BOX CARPET
36. REMOVE BOX PANEL NO.3
37. REMOVE CONSOLE BOX ASSEMBLY
38. REMOVE INSTRUMENT PANEL BRACE SUB-ASSEMBLY NO.2
39. REMOVE INSTRUMENT PANEL BRACE SUB-ASSEMBLY NO.1
40. REMOVE FRONT PILLAR GARNISH RH
41. REMOVE FRONT PILLAR GARNISH LH
42. REMOVE INSTRUMENT SIDE PANEL RH
43. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY
44. REMOVE AIRBAG SENSOR ASSEMBLY CENTER
a. Remove the 3 bolts and airbag sensor.
45. REMOVE HEATER TO REGISTER DUCT NO.2
a. Using a screwdriver, detach the 4 claws and remove the duct.
HINT: Tape the screwdriver tip before use.
46. REMOVE AIR CONDITIONER UNIT ASSEMBLY
a. Detach the 2 clamps and disconnect the wire harness.
b. Remove the 2 screws, 3 nuts, bolt and A/C unit.
47. REMOVE HEATER BRACKET
a. Using a screwdriver, detach the claw and disconnect the connector.
HINT: Tape the screwdriver tip before use.
b. Remove the 2 bolts and heater bracket.
48. REMOVE AIR CONDITIONING RADIATOR ASSEMBLY
a. Disconnect the connector and clamp of the blower.
b. Using a screwdriver, detach the claw and disconnect the connector.
HINT: Tape the screwdriver tip before use.
c. Remove the 2 screws, detach the claw and remove the A/C radiator.
49. REMOVE COOLER THERMISTOR HOSE
50. REMOVE AIR DUCT NO.1
a. Remove the 2 screws and air duct.
51. REMOVE AIR DUCT NO.2
a. Remove the 2 screws and air duct.
52. REMOVE AIR DUCT NO.3
a. Using a screwdriver, detach the claw and remove the air duct.
HINT: Tape the screwdriver tip before use.
53. REMOVE AIR DUCT NO.4
a. Using a screwdriver, detach the claw and remove the air duct.
HINT: Tape the screwdriver tip before use.
54. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY
a. Remove the screw and clamp.
b. Remove the heater radiator unit from the A/C radiator.
55. REMOVE COOLER UNIT DRAIN HOSE NO.1
56. REMOVE BLOWER MOTOR CONTROL
a. Disconnect the 2 connectors.
b. Remove the screw and blower motor control.
57. REMOVE AIR CONDITIONING WIRING HARNESS SUB-ASSEMBLY
a. Release the 2 claws, and then disconnect the 4 connectors.
b. Remove the A/C wiring harness.
58. REMOVE DAMPER SERVO SUB-ASSEMBLY
a. Remove the 3 screws and damper servo.
59. REMOVE AIR MIX DAMPER SERVO SUB-ASSEMBLY
a. Remove the 3 screws and air mix damper servo.
60. REMOVE MODE DAMPER SERVO SUB-ASSEMBLY
a. Remove the 2 screws and mode damper servo.
61. REMOVE DAMPER SERVO SUB-ASSEMBLY
a. Disconnect the rod from the damper servo.
b. Remove the 2 screws and damper servo.
62. REMOVE AIR CONDITIONING TUBE ASSEMBLY
a. Using a 4 mm hexagon wrench, remove the 2 hexagon bolts and A/C tube.
63. REMOVE COOLER EXPANSION VALVE
a. Using a 4 mm hexagon wrench, remove the 2 bolts, A/C tube & accessory, cooler expansion valve and tube connector.
b. Remove the 4 O-rings.
64. REMOVE COOLER EVAPORATOR SUB-ASSEMBLY NO.1
a. Remove the 6 screws and No. 1 cooler cover.
b. Pull out the cooler evaporator.
c. Remove the 2 O-rings from the cooler evaporator.
65. INSTALL COOLER EVAPORATOR SUB-ASSEMBLY NO.1
a. Sufficiently apply compressor oil to 2 new O-rings and the contact surface of the cooler evaporator.
Compressor oil: ND-OIL 8 or equivalent
b. Install the cooler evaporator to the A/C radiator.
c. Install the No. 1 cooler cover with the 6 screws.
66. INSTALL COOLER EXPANSION VALVE
a. Sufficiently apply compressor oil to 4 new O-rings and the contact surface of the A/C tube & accessory and tube connector.
Compressor oil: ND-OIL 8 or equivalent
b. Using a 4 mm hexagon wrench, install the A/C tube & accessory, cooler expansion valve and tube connector with the 2 bolts.
Torque: 4.1 N.m (42 kgf.cm, 36 in.lbf)
67. INSTALL AIR CONDITIONING TUBE ASSEMBLY
a. Using a 4 mm hexagon wrench, install the A/C tube & accessory with the 2 bolts.
Torque: 4.1 N.m (42 kgf.cm, 36 in.lbf)
b. Sufficiently apply compressor oil to a new O-ring and the contact surface of the A/C tube.
Compressor oil: ND-OIL 8 or equivalent
68. INSTALL AIR CONDITIONER UNIT ASSEMBLY
a. Install the A/C unit with the 2 screws, 3 nuts and bolt.
Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
b. Install the wire harness to the A/C unit with the 2 clamps.
69. INSTALL AIRBAG SENSOR ASSEMBLY CENTER
a. Install the airbag sensor with the 3 bolts.
Torque: 20 N.m (200 kgf.cm, 14 ft.lbf)
70. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY
71. INSTALL INSTRUMENT PANEL BRACE SUB-ASSEMBLY NO.2
72. INSTALL INSTRUMENT PANEL BRACE SUB-ASSEMBLY NO.1
73. INSTALL CONSOLE BOX ASSEMBLY
74. CENTER SPIRAL CABLE
75. INSTALL STEERING WHEEL ASSEMBLY
76. INSPECT STEERING WHEEL CENTER POINT
77. INSPECT HORN BUTTON ASSEMBLY
78. INSTALL HORN BUTTON ASSEMBLY
79. INSPECT SRS WARNING LAMP
80. INSTALL COOLER REFRIGERANT LIQUID PIPE A
a. Sufficiently apply compressor oil to a new O-ring and the contact surface of the refrigerant liquid pipe.
Compressor oil: ND-OIL 8 or equivalent
b. Install the O-ring to the liquid pipe.
c. Connect the liquid pipe.
81. INSTALL COOLER REFRIGERANT SUCTION PIPE NO.1
a. Sufficiently apply compressor oil to a new O-ring and the contact surface of the suction pipe.
Compressor oil: ND-OIL 8 or equivalent
b. Install the O-ring to the suction pipe.
c. Connect the suction pipe.
d. Slide the plate, and install the bolt.
Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
82. ADD ENGINE COOLANT
83. CHECK FOR ENGINE COOLANT LEAKS
84. CHARGE REFRIGERANT
85. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
86. PERFORM INITIALIZATION
NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable the negative (-) battery terminal.
87. WARM UP ENGINE
88. CHECK FOR LEAKAGE OF REFRIGERANT