Evaporator Case: Service and Repair
Air Conditioning Radiator Assy Part 1:
Air Conditioning Radiator Assy Part 2:
Air Conditioning Radiator Assy Part 3:
Air Conditioning Radiator Assy Part 4:
OVERHAUL
1. DRAIN REFRIGERANT
SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
2. SEPARATE COOLER REFRIGERANT SUCTION PIPE NO.1
a. Remove the bolt and slide the plate, disconnect the cooler refrigerant suction pipe No.1.
b. Disconnect the cooler refrigerant suction pipe No.1
NOTE:
- Do not use tools like screwdriver to remove the tube.
- Cap the open fittings immediately to keep moisture or dirt out of the system.
3. SEPARATE COOLER REFRIGERANT LIQUID PIPE A
a. Disconnect the cooler refrigerant liquid pipe A.
NOTE:
- Do not use tools like screwdriver to remove the tube.
- Cap the open fittings immediately to keep moisture or dirt out of the system.
4. SEPARATE HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
a. Slide the clip, disconnect the heater water outlet hose A (from heater unit).
5. SEPARATE HEATER WATER INLET HOSE A
a. Slide the clip, disconnect the heater water inlet hose A.
6. SHIP MODE SETTING (W/ CD CHANGER)
7. SEPARATE BATTERY NEGATIVE TERMINAL
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 ASSY
13. REMOVE STEERING WHEEL ASSY
SST 09950-50012 (09951-05010, 09952-05010, 09953-05020, 09954-05020)
14. REMOVE DOOR SCUFF PLATE ASSY RH
15. REMOVE DOOR SCUFF PLATE ASSY LH
16. REMOVE FRONT DOOR OPENING TRIM COVER RH
17. REMOVE FRONT DOOR OPENING TRIM COVER LH
18. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY NO.1
19. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY
20. REMOVE STEERING COLUMN COVER LWR
21. REMOVE STEERING COLUMN COVER UPR
22. REMOVE TURN SIGNAL SWITCH ASSY
23. REMOVE COMBINATION METER ASSY
24. REMOVE CONSOLE UPPER PANEL GARNISH REAR
25. REMOVE CONSOLE PANEL SUB-ASSY UPPER
26. REMOVE AIR CONDITIONER CONTROL ASSY
27. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY LOWER CENTER
28. SHIP MODE CONFIRMATION (W/ CD CHANGER)
Refer to Radio/Stereo; Service and Repair.
29. REMOVE INSTRUMENT PANEL SAFETY PAD GARNISH SUB-ASSY (W/O LEXUS NAVIGATION SYSTEM)
30. REMOVE INSTRUMENT PANEL SAFETY PAD GARNISH SUB-ASSY (W/ LEXUS NAVIGATION SYSTEM)
31. REMOVE INSTRUMENT PANEL GARNISH SUB-ASSY NO.2 (W/ LEXUS NAVIGATION SYSTEM)
32. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY CENTER (W/ LEXUS NAVIGATION SYSTEM)
33. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.2
34. REMOVE GLOVE COMPARTMENT DOOR ASSY
35. REMOVE CONSOLE BOX CARPET
36. REMOVE BOX PANEL NO.3
37. REMOVE CONSOLE BOX ASSY
38. REMOVE INSTRUMENT PANEL BRACE SUB-ASSY NO.2
39. REMOVE INSTRUMENT PANEL BRACE SUB-ASSY 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-ASSY
44. SEPARATE AIR BAG SENSOR ASSY CENTER
a. Remove the 3 bolts and separate the airbag sensor assy center.
45. REMOVE HEATER TO REGISTER DUCT NO.2
a. Release the 4 claws, remove the heater to register duct No.2.
46. REMOVE AIR CONDITIONER UNIT ASSY
a. Remove the wire harness clamps, disconnect the wire harness from the air conditioner unit assy.
b. Remove the 2 screws, 3 nuts, bolt and air conditioner unit assy.
47. REMOVE HEATER BRACKET
a. Release the claw, separate the connector.
b. Remove the 2 bolts and heater bracket.
48. REMOVE AIR CONDITIONING RADIATOR ASSY
a. Disconnect the connector and clamp of the blower assy.
b. Release the claw, disconnect the connector from the bracket.
c. Remove the 2 screws, release the claw of the air conditioning radiator assy.
d. Remove the air conditioning radiator assy.
49. REMOVE COOLER THERMISTOR HOSE
50. REMOVE AIR DUCT NO.1
a. Remove the 2 screws and air duct No.1.
51. REMOVE AIR DUCT NO.2
a. Remove the 2 screws and air duct No.2.
52. REMOVE AIR DUCT NO.3
a. Release the claw, remove the air duct No.3.
53. REMOVE AIR DUCT NO.4
a. Release the claw, remove the air duct No.4.
54. REMOVE HEATER RADIATOR UNIT SUB-ASSY
a. Remove the screw and clamp.
b. Remove the heater radiator unit sub-assy from the air conditioning radiator assy.
55. REMOVE COOLER UNIT DRAIN HOSE NO.1
56. REMOVE BLOWER MOTOR CONTROL
a. Remove the screw and blower motor control.
57. REMOVE WIRING AIR CONDITIONING HARNESS SUB-ASSY
58. REMOVE WIRING AIR CONDITIONING HARNESS SUB-ASSY
a. Release the claws, disconnect the 4 connectors.
b. Remove the wiring air conditioning harness sub-assy.
c. Remove the No.1 cooler thermistor.
59. REMOVE DAMPER SERVO SUB-ASSY
a. Remove the 3 screws and damper servo sub-assy.
60. REMOVE AIRMIX DAMPER SERVO SUB-ASSY
a. Remove the 3 screws and airmix damper servo sub-assy.
61. REMOVE MODE DAMPER SERVO SUB-ASSY
a. Remove the 2 screws and mode damper servo sub-assy.
62. REMOVE DAMPER SERVO SUB-ASSY
a. Disconnect the rod from the damper servo sub-assy.
b. Remove the 2 screws and damper servo sub-assy.
63. REMOVE AIR CONDITIONING TUBE & ACCESSORY ASSY
a. Pry out the packing.
b. Using a hexagon wrench 4, remove the 2 bolts and air conditioning tube & accessory assy.
64. REMOVE COOLER EXPANSION VALVE
a. Using a hexagon wrench 4, separate the cooler expansion valve, tube connector and air conditioning tube & accessory assy.
b. Remove the 4 O-rings.
65. REMOVE COOLER EVAPORATOR SUB-ASSY NO.1
a. Remove the 6 screws and No.1 cooler cover.
b. Pull out the cooler evaporator sub-assy No.1.
c. Remove the 2 O-rings from the cooler evaporator sub-assy No.1.
66. INSTALL COOLER EVAPORATOR SUB-ASSY NO.1
a. Lubricate the 2 new O-rings with compressor oil, install them to the cooler evaporator sub-assy No.1.
Compressor oil: ND-OIL 8 or equivalent
b. Install the cooler evaporator sub-assy No.1 to the air conditioner radiator assy.
c. Install the No.1 cooler cover and 6 screws.
67. INSTALL COOLER EXPANSION VALVE
a. Lubricate the 4 new O-rings with compressor oil, install them to the air conditioning tube & accessory assy and tube connector.
Compressor oil: ND-OIL 8 or equivalent
b. Using a hexagon wrench 4, install the air conditioning tube & accessory assy, tube connector and 2 bolts to the cooler expansion valve.
Torque: 4.1 N.m (42 kgf.cm, 36 in.lbf)
68. INSTALL AIR CONDITIONING TUBE & ACCESSORY ASSY
a. Using a hexagon wrench 4, install the air conditioning tube & accessory assy and 2 bolts.
Torque: 4.1 N.m (42 kgf.cm, 36 in.lbf)
b. Install new packing to the air conditioning tube & accessory assy.
69. INSTALL AIR CONDITIONER UNIT ASSY
a. Install the 2 screws, 3 nuts and air conditioner unit assy.
b. Install the bolt to the air conditioner unit assy.
Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
c. Connect the clamps to the air conditioner unit assy.
70. INSTALL AIR BAG SENSOR ASSY CENTER
a. Install the 3 bolts and airbag sensor assy center.
Torque: 20 N.m (200 kgf.cm, 14 ft.lbf)
71. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY
72. INSTALL INSTRUMENT PANEL BRACE SUB-ASSY NO.2
73. INSTALL INSTRUMENT PANEL BRACE SUB-ASSY NO.1
74. INSTALL CONSOLE BOX ASSY
75. CENTER SPIRAL CABLE
76. INSTALL STEERING WHEEL ASSY
77. INSPECT STEERING WHEEL CENTER POINT
78. INSPECT HORN BUTTON ASSY
79. INSTALL HORN BUTTON ASSY
80. INSPECT SRS WARNING LIGHT
81. INSTALL COOLER REFRIGERANT LIQUID PIPE A
a. Lubricate new O-ring with compressor oil, install them to the cooler refrigerant liquid pipe A.
Compressor oil: ND-OIL 8 or equivalent
b. Connect the cooler refrigerant liquid pipe A.
82. INSTALL COOLER REFRIGERANT SUCTION PIPE NO.1
a. Lubricate new O-ring with compressor oil, install them to the cooler refrigerant suction pipe No.1.
Compressor oil: ND-OIL 8 or equivalent
b. Connect the cooler refrigerant suction pipe No.1.
c. Slide the plate, install the bolt.
Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
83. ADD COOLANT
84. CHECK ENGINE COOLANT LEAK
85. CHARGE REFRIGERANT
SST 07117-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-78060, 07117-78070, 07117-78080)
Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.)
86. WARM UP ENGINE
87. INSPECT LEAKAGE OF REFRIGERANT