FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.
Home >> Lexus >> 2006 >> LS 430 V8-4.3L (3UZ-FE) >> Repair and Diagnosis >> Heating and Air Conditioning >> Heater Core >> Service and Repair

Heater Core: Service and Repair

Air Conditioning Radiator Assy Part 1:




Air Conditioning Radiator Assy Part 2:






AIR CONDITIONING RADIATOR ASSEMBLY OVERHAUL


HINT:
- Installation is in the reverse order of removal.

1. DISCONNECT NEGATIVE TERMINAL CABLE FROM BATTERY
2. EVACUATE REFRIGERANT HFC-134A (R134A)
3. DRAIN ENGINE COOLANT FROM RADIATOR

HINT: It is not necessary to drain out all coolant.

4. REMOVE V-BANK COVER




5. DISCONNECT SUCTION TUBE SUB-ASSEMBLY B
a. Remove the bolts and slide the plate. Disconnect suction tube sub-assembly B.

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

b. Remove the O-ring.

6. DISCONNECT LIQUID TUBE SUB-ASSEMBLY A
a. Disconnect liquid tube sub-assembly A.

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

b. Remove the O-ring.




7. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
a. Grip the claws of the hose clip and slide the hose clip along the hose.
b. Disconnect heater water outlet hose A.

NOTE:
- Do not apply any excessive force to the heater water outlet hose.
- Prepare a drain pan or cloth for when the cooling water leaks

8. DISCONNECT HEATER WATER INLET HOSE B
a. Disconnect heater water inlet hose B.

9. DISCONNECT WATER VALVE CONTROL CABLE
10. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY
11. REMOVE BLOWER ASSEMBLY

12. REMOVE SEAT




13. SEPARATE AIR DUCT REAR NO.1
a. Remove the 2 screws, bolt and center air duct.
b. Remove the 2 hole covers, 2 screws and air duct rear No.1.

14. SEPARATE AIR DUCT REAR NO.2
a. Remove the 2 hole covers, 2 screws and air duct No.2.




15. SEPARATE CONSOLE BOX DUCT NO.1
a. Slide the floor carpet backward.
b. Disconnect the wire harness clamp.
c. Remove the 4 nuts and console box duct No.1.




16. REMOVE AIR CONDITIONING RADIATOR ASSEMBLY
a. Disconnect the connectors and wire harness clamps.
b. Remove the 2 nuts, bolt and air conditioning radiator assembly.

17. REMOVE HEATER CASE SUB-ASSEMBLY




a. Remove the 5 screws, release the 2 claws and remove the air vent duct.




b. Remove the 5 screws.




c. Using a screwdriver, release the 2 claws and remove the heater case sub-assembly.

18. REMOVE COOLER EXPANSION VALVE




a. Using a hexagon wrench 5 mm (0.20 in.), remove the 2 hexagon bolts and air conditioning tube assembly.
b. Remove the 2 O-rings from the air conditioning tube assembly.




c. Using a hexagon wrench 5 mm (0.20 in.), remove the 2 hexagon bolts and cooler expansion valve.
d. Remove the 4 O-rings from the cooler expansion valve.




19. REMOVE COOLER EVAPORATOR SUB-ASSEMBLY NO.1
a. Remove the 6 screws and evaporator cover.
b. Pull out the evaporator.

20. REMOVE EVAPORATOR TEMPERATURE SENSOR




21. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY
a. Remove the screw and clamp.
b. Remove the 2 screws, 2 clamps and heater radiator pipes.
c. Remove the 2 O-rings from the heater radiator pipes.
d. Pull out the heater radiator unit sub-assembly.




22. REMOVE WATER VALVE CONTROL SERVOMOTOR
a. Disconnect the connector.
b. Disconnect the control cable.
c. Remove the 2 screws and water valve control servomotor.




23. REMOVE COOL AIR BYPASS SERVOMOTOR
a. Remove the 3 screws and cool air bypass servomotor.
b. Employ the same manner described above to the other side.




24. REMOVE AIR MIX SERVOMOTOR
a. Remove the 3 screws and air mix servomotor.
b. Employ the same manner described above to the other side.







25. REMOVE AIR OUTLET SERVOMOTOR
a. Driver side:
Remove the 3 screws and bracket.
b. Remove the 3 screws and air outlet servomotor.
c. Employ the same manner described above to the other side.

26. REMOVE WIRING AIR CONDITIONING HARNESS SUB-ASSEMBLY




27. INSTALL COOLER EXPANSION VALVE
a. Sufficiently apply compressor oil to 4 new O-rings and fitting surface of the cooler expansion valve.
Compressor oil: ND-OIL 8 or equivalent
b. Install the 4 O-rings to the cooler expansion valve.
c. Using a hexagon wrench 5 mm (0.20 in.), install the cooler expansion valve with the 2 hexagon bolts.

Torque: 4.1 Nm (42 kgf.cm, 36 ft.lbf)




d. Sufficiently apply compressor oil to 2 new O-rings and fitting surface of the cooler expansion valve.
Compressor oil: ND-OIL 8 or equivalent
e. Install the 2 O-rings to the cooler expansion valve.
f. Using a hexagon wrench 5 mm (0.20 in.), install the cooler expansion valve with the 2 hexagon bolts.

Torque: 4.1 Nm (42 kgf.cm, 36 ft.lbf)




28. INSTALL COOLER EVAPORATOR SUB-ASSEMBLY NO.1
a. Install the cooler evaporator sub-assembly No.1 with the evaporator cover and 6 screws.

29. INSTALL HEATER CASE SUB-ASSEMBLY




a. Install the heater case sub-assembly with the 5 screws.




b. Install the air duct with the 5 screws.




30. TEMPORARILY INSTALL AIR CONDITIONING RADIATOR ASSEMBLY
a. Temporarily install the air conditioning radiator assembly with the 2 bolts and nut.




31. FULLY INSTALL AIR CONDITIONING RADIATOR ASSEMBLY
a. Fully install the air conditioning radiator assembly with the 2 bolts and nut.

32. INSTALL BLOWER ASSEMBLY
33. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY




34. AFTER INSTALLATION, CHECK WATER VALVE OPERATION
a. Turn the ignition switch to the ON position.
b. Set the temperature control switch to "MAX. COOL" and "MAX. WARM" and check the water valve operates as shown in the illustration.
If operation is not as specified, proceed to the next step.

35. ADJUST WATER VALVE CONTROL CABLE
a. Turn the ignition switch to the ON position.
b. Disconnect the control cable.
c. Set the temperature control switch to "MAX. COOL".




d. Set the water valve lever to the "COOL" position, connect the control cable and lock the clamp.

HINT: Lock the clamp while lightly pushing the outer cable in the direction shown in the illustration by an arrow.

36. CONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
a. Connect the heater water outlet hose A.

NOTE:
- Do not apply any excessive force to the heater water outlet hose.
- Prepare a drain pan or cloth for when the cooling water leaks.







37. CONNECT HEATER WATER INLET HOSE B
a. Connect the heater water inlet hose B.

NOTE:
- Do not apply any excessive force to the heater water outlet hose.
- Prepare a drain pan or cloth for when the cooling water leaks.

b. Grip the claws of the hose clip and slide the hose clip along the hose.

HINT:
- Push the water hose onto the heater radiator pipe as far as the second ridge on the pipe and install the hose clip.
- Install the hose clip in the position, as shown in the illustration.

38. INSTALL LIQUID TUBE SUB-ASSEMBLY A
a. Sufficiently apply compressor oil to a new O-ring.
Compressor oil: ND-OIL 8 or equivalent
b. Install the O-ring.




39. INSTALL SUCTION TUBE SUB-ASSEMBLY B
a. Sufficiently apply compressor oil to a new O-ring.
Compressor oil: ND-OIL 8 or equivalent
b. Install the O-ring.
c. Connect the suction tube sub-assembly B and slide the plate.
d. Install a bolt.

Torque: 10 Nm (100 kgf.cm, 7 ft.lbf)

40. CONNECT NEGATIVE TERMINAL CABLE TO BATTERY
41. ADD ENGINE COOLANT
42. CHARGE REFRIGERANT
43. WARM UP ENGINE
44. CHECK FOR ENGINE COOLANT LEAKS
45. INSPECT FOR REFRIGERANT LEAKAGE
pro multis Credits:Operation CHARM About Operation CHARM