Air Conditioning: Removal & Installation Lexus GS III

INSTALLATION

Installation is in the reverse order of removal (See REMOVAL ).

AFTER INSTALLATION, CHECK DRIVE BELT'S INSTALLATION CONDITION

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1. CONNECT CHARGING HOSES TO MANIFOLD GAUGE SET Tighten the nuts by hand. CAUTION: Do not connect the wrong hoses.
2. CONNECT QUICK DISCONNECT ADAPTERS TO CHARGING HOSES Tighten the nuts by hand.
3. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET
4. REMOVE CAPS FROM SERVICE VALVE ON REFRIGERANT LINES
5. CONNECT QUICK DISCONNECT ADAPTERS TO SERVICE VALVES HINT: Push the quick disconnect adapter onto the service valve, then slide the sleeve of the quick disconnect adapter downward to lock it.

Scheme 154

1. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET
2. DISCONNECT QUICK DISCONNECT ADAPTERS FROM SERVICE VALVES ON REFRIGERANT LINE HINT: Slide the sleeve of the quick disconnect adapter upward to unlock the adapter and remove it from the service valve.
3. INSTALL CAPS TO SERVICE VALVES ON REFRIGERANT LINES

REPLACEMENT

1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
2. REPLACE FAULTY TUBE OR HOSE NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system.
3. TIGHTEN JOINT OF BOLT OR NUT TO SPECIFIED TORQUE NOTE: Connections should not be torqued tighter than the specified torqued. NUT BOLT TORQUE SPECIFIED Part tightened N.m kgf.cm ft.lbf Compressor x Discharge hose 10 100 7 Compressor x Suction hose 10 100 7 Condenser x Discharge hose 10 100 7 Condenser x Liquid tube 10 100 7 A/C unit x Liquid and Suction tubes 10 100 7 Expansion valve x Liquid and suction tube 4.1 42 36 in.lbf Evaporator x Liquid and suction tube 4.1 42 36 in.lbf Suction line (Block joint) 10 100 7
4. EVACUATE AIR FROM REFRIGERATION SYSTEM AND CHARGE SYSTEM WITH REFRIGERANT Specified amount: 600 +/- 50 g (21.16 +/- 1.76 oz.)
5. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant.
6. INSPECT AIR CONDITIONING OPERATION

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1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 600 +/- 50 g (21.16 +/-.76 oz.)
2. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all coolant.
3. DISCONNECT LIQUID TUBE AND SUCTION HOSE FROM A/C UNIT Remove the bolt and slide the plate, then disconnect the both tubes. Torque: 10 N.m (100 kgf.cm, 7 ft.lbf) NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system. HINT: At the time of installation, please refer to the following item. Lubricate 2 new O-rings with compressor oil and install them to the tubes.
4. DISCONNECT WATER HOSES FROM HEATER RADIATOR PIPES Grip the claws of the hose clip and slide the hose clip along the hose. Disconnect the water hose.
5. REMOVE THESE PARTS: Cooler No.1 grommet Heater pipe grommet Drain hose grommet Instrument panel and reinforcement (See «REMOVAL»(ref-229437-S30123028692006041500000) ) Blower unit (See «REMOVAL»(ref-229445-S20682745822006041500000) )
6. REMOVE 3 AIR DUCTS Remove the 2 screws and center air duct. Slide the floor carpet backward. Disconnect the wire harness clamps. Remove the 2 bolts and air ducts LH, RH.
7. REMOVE A/C UNIT Disconnect the connector. Remove the wire harness set nut. Disconnect the wire harness clamps. Remove the 2 nuts, bolt and A/C unit.

Installation is in the reverse order of removal (See REMOVAL ).

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1. REMOVE INSTRUMENT PANEL AND REINFORCEMENT (See «REMOVAL»(ref-229437-S30123028692006041500000) )
2. REMOVE AIR DUCT Disconnect the connector clamp. Remove the 3 screws and air duct.
3. DISCONNECT WIRE HARNESS Release the claw of the connector bracket and disconnect the connector bracket. Disconnect the wire harness set clamps. Disconnect the wire harness.
4. REMOVE BLOWER UNIT Disconnect the connectors. Remove the 2 bolts and bracket. Remove the bolt, screw and nut. Remove the blower unit.

Installation is in the reverse order of removal (See REMOVAL ).

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1. INSPECT COMPRESSOR FOR METALLIC SOUND Check there is abnormal metallic sound from the compressor when the A/C switch is ON. If abnormal metallic sound is heard, replace the compressor assembly.
2. INSPECT REFRIGERANT PRESSURE (See «ON-VEHICLE INSPECTION»(ref-229445-S40850786612006041500000) )
3. INSPECT VISUALLY FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant. If there is any leakage, replace the compressor assembly.
4. INSPECT COMPRESSOR LOCK SENSOR RESISTANCE Disconnect the connector. Measure resistance between terminals 1 and 2. Standard resistance: 570 - 1,050 ohm at 20°C (68 °F) If resistance is not as specified, replace the compressor.
5. MAKE THESE VISUAL CHECKS: Leakage of grease from the clutch bearing. Signs of oil on the pressure plate or rotor.
6. INSPECT MAGNETIC CLUTCH BEARING FOR NOISE Start engine. Check for abnormal noise from the compressor when the A/C switch is OFF. If abnormal noise is being emitted, replace the rotor of magnetic clutch.
7. INSPECT MAGNETIC CLUTCH OPERATION Disconnect the connector. Connect the positive (+) lead from the battery to terminal and the negative (-) lead to the body ground. Check that the magnetic clutch is energized. If operation is not as specified, replace the magnetic clutch.

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1. RUN ENGINE AT IDLE SPEED WITH A/C ON FOR APPROX. 10 MINUTES
2. STOP ENGINE
3. DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY
4. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
5. REMOVE ENGINE UNDER COVER
6. REMOVE DRIVE BELT (See «REMOVAL»(ref-229445-S22710527422006041500000) )
7. GS430:DISCONNECT DISCHARGE HOSE Remove the nut and disconnect the discharge hose. NOTE: Cap the open fitting immediately to keep moisture or dirt out of the system.
8. GS430:REMOVE SUCTION HOSE Remove the nut, bolt and suction hose. NOTE: Cap the open fitting immediately to keep moisture or dirt out of the system.
9. GS300:DISCONNECT DISCHARGE AND SUCTION HOSES Remove the 2 nut and disconnect the both hoses. NOTE: Cap the open fitting immediately to keep moisture or dirt out of the system.
10. GS300:REMOVE 2 PS PUMP SET BOLTS
11. GS300:REMOVE COMPRESSOR Remove the bolt and PS pump bracket. Remove the 2 bolts and compressor bracket. Disconnect the connector. Remove the nut and 3 bolts. Using a torx socket (E10), remove the stud bolt and compressor.
12. GS430:REMOVE COMPRESSOR Disconnect the connector. Remove the nut, bolt and compressor stay. Remove the 2 bolts and compressor.

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1. REMOVE PRESSURE PLATE Using SST and a socket wrench, remove the shaft bolt. SST 07112-76060 Torque: 18 N.m (184 kgf.cm, 13.2 ft.lbf) Install SST on the pressure plate. SST 07112-66040 Using SST and socket wrench, remove the pressure plate SST 07112-66040, 07112-76060 Remove the shims from the pressure plate.
2. REMOVE ROTOR Using SST, remove the snap ring. SST 95994-10020 NOTE: At the time of reassembly, please refer to the following item. The snap ring should be installed so that beveled side faces up. Using a plastic hammer, tap the rotor off the shaft. NOTE: Be careful not to damage the pulley when tapping on the rotor.
3. REMOVE STATOR Disconnect the stator lead wire from the compressor housing. Using SST, remove the snap ring. SST 95994-10020 NOTE: At the time of reassembly, please refer to the following item. The snap ring should be installed so that its beveled side faces up. Remove the stator.

1. GS430:INSTALL COMPRESSOR Install the compressor with the 2 bolts temporarily. Install the compressor stay with the bolt and nut temporarily. Tighten the nut and 3 bolts. Torque: Bolt: 49 N.m (500 kgf.cm, 36 ft.lbf) Nut: 29 N.m (300 kgf.cm, 22 ft.lbf) Connect the connector.
2. GS300:INSTALL COMPRESSOR Install the compressor with the stud bolt. Torque: 52 N.m (530 kgf.cm, 38 ft.lbf) Install the 3 bolts and nut. Torque: Bolt: 52 N.m (530 kgf.cm, 38 ft.lbf) Nut: 26 N.m (265 kgf.cm, 19 ft.lbf) Connect the connector. Install the compressor bracket with the 2 bolts. Torque: 52 N.m (530 kgf.cm, 38 ft.lbf) Install the PS pump bracket with the 2 bolts. Torque: 52 N.m (530 kgf.cm, 38 ft.lbf)
3. GS300:INSTALL 2 PS PUMP SET BOLTS Torque: 58 N.m (590 kgf.cm, 43 ft.lbf)
4. GS300:CONNECT DISCHARGE AND SUCTION HOSES Connect both the hoses with the 2 nuts. Torque: 10 N.m (100 kgf.cm, 7 ft.lbf) NOTE: Hose should be connected immediately after the caps have been removed. HINT: Lubricate 2 new O-rings with compressor oil and install them to the hoses.
5. GS430:CONNECT DISCHARGE HOSE Connect the discharge hose with the nut. Torque: 10 N.m (100 kgf.cm, 7 ft.lbf) NOTE: Hose should be connected immediately after the cap have been removed. HINT: Lubricate a new O-ring with compressor oil and install them to the hose.
6. GS430:INSTALL SUCTION HOSE Install the suction hose with the bolt and nut. Torque: 10 N.m (100 kgf.cm, 7 ft.lbf) NOTE: Hose should be connected immediately after the caps have been removed. HINT: Lubricate 2 new O-rings with compressor oil and install them to the hose.
7. INSTALL DRIVE BELT (See «INSTALLATION»(ref-229445-S16970741852006041500000) )
8. INSPECT DRIVE BELT TENSION (See «DRIVE BELT»(ref-229445-S35866698752006041500000) )
9. INSTALL ENGINE UNDER COVER
10. CONNECT NEGATIVE (-) TERMINAL CABLE TO BATTERY
11. EVACUATE AIR FROM REFRIGERATION SYSTEM AND CHARGE SYSTEM WITH REFRIGERANT Specified amount: 600 +/- 50 g (21.16 +/- 1.76 oz.)
12. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant. If there is leakage, check the tightening torque at the joints.
13. INSPECT A/C OPERATION

Installation is in the reverse order of removal (See REMOVAL ).

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1. REMOVE A/C UNIT (See «REMOVAL»(ref-229445-S32249559372006041500000) )
2. REMOVE HEATER RADIATOR (See «REMOVAL»(ref-229445-S05872894292006041500000) )
3. REMOVE AIR MIX SERVOMOTOR PASSENGER SIDE Disconnect the connector. Remove the 3 screws and servomotor.
4. REMOVE TUBE AND ACCESSORY Pry out packing. HINT: At the time of installation, please refer to the following item. Do not reuse the packing. Using SST, remove the 2 bolts and the tube and accessory. SST 07110-61050 Torque: 4.1 N.m (42 kgf.cm, 36 in.lbf) NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system. HINT: At the time of installation, please refer to the following item. Lubricate 2 new O-rings with compressor oil and install them to the tube. Remove screw and drain pipe.
5. REMOVE EVAPORATOR Disconnect the connector from blower motor control relay. Remove the screw and drain hose. Remove the 4 screws and cover. Pull out the evaporator. HINT: At the time of installation, please refer to the following item. If evaporator is replaced, add compressor oil to evaporator. Add 40 cc (1.4 fl. oz.) Compressor oil: ND-OIL 8 or equivalent

Installation is in the reverse order of removal (See REMOVAL ).

Scheme 193

1. REMOVE A/C UNIT (See «REMOVAL»(ref-229445-S32249559372006041500000) )
2. REMOVE HEATER RADIATOR Remove the screw and clamp. Pull out the heater radiator.

Installation is in the reverse order of removal (See REMOVAL ).

Installation is in the reverse order of removal (See REMOVAL ).

Scheme 194

1. REMOVE No.2 UNDER COVER (See «REMOVAL»(ref-229437-S30123028692006041500000) )
2. REMOVE BLOWER MOTOR Disconnect the connector. Remove the 3 screws and blower motor.

Installation is in the reverse order of removal (See REMOVAL ).

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1. REMOVE THESE PARTS: Front door scuff plate RH Cowl side trim RH No.2 under cover Glove compartment door Glove compartment panel (See «REMOVAL»(ref-229437-S30123028692006041500000) )
2. REMOVE AIR DUCT Remove the 3 screws and duct.
3. DISCONNECT WIRE HARNESS
4. REMOVE BLOWER MOTOR CONTROL RELAY Remove the screw and blower motor control relay, then disconnect the connectors.

Installation is in the reverse order of removal (See REMOVAL ).

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1. REMOVE AIR INLET SERVOMOTOR Remove these parts: Front door scuff plate RH Cowl side trim RH No.2 under cover Glove compartment door Glove compartment panel (See «REMOVAL»(ref-229437-S30123028692006041500000) ) Disconnect the wire harness. Remove the bracket. Disconnect wire harness clamp. Remove the 2 bolts and bracket. Remove the air inlet servomotor. Disconnect the connector. Remove the 3 screws and servomotor.
2. REMOVE AIR MIX SERVOMOTOR (Driver Side) Remove these parts: No.1 under cover No.1 safety pad (See «REMOVAL»(ref-229437-S30123028692006041500000) ) Remove the air mix servomotor. Disconnect the connector. Remove the 3 screws and servomotor.
3. REMOVE AIR MIX SERVOMOTOR (Passenger Side) Remove heater radiator (See «REMOVAL»(ref-229445-S05872894292006041500000) ). Remove the air mix servomotor. Disconnect the connector. Remove the 3 screws and servomotor.
4. REMOVE AIR OUTLET SERVOMOTOR Remove these parts: No. 2 under cover Glove compartment door Glove compartment panel (See «REMOVAL»(ref-229437-S30123028692006041500000) ) Remove the air duct. Remove the 3 screws and air duct. Remove air outlet servomotor. Disconnect the connector. Remove the 2 screws and servomotor.

Installation is in the reverse order of removal (See SERVOMOTOR ).

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1. REMOVE SOLAR SENSOR Using a screw driver, pull out the sensor and disconnect the connector. HINT: Tape the screwdriver tip before use. At the time of installation, please refer to the following item. Insert the sensor to instrument panel (Scheme 205)
2. REMOVE ROOM TEMPERATURE SENSOR Remove the No. 1 under cover. (See «REMOVAL»(ref-229437-S30123028692006041500000) ) Remove the room temperature sensor. Remove the No.1 safety pad set bolts and screws. Disconnect the connector and aspirator hose. Remove the screw and sensor.
3. REMOVE AMBIENT TEMPERATURE SENSOR Disconnect the connector. Using a clip remover, pull out the sensor from bumper reinforcement.
4. REMOVE EVAPORATOR TEMPERATURE SENSOR Remove these parts: No.1 under cover No.1 safety pad (See «REMOVAL»(ref-229437-S30123028692006041500000) ) Remove the evaporator temperature sensor. Using a screwdriver, pull out the sensor with bracket plate. HINT: Tape the screwdriver tip before use. Release the 2 claws and remove the sensor from bracket plate.
5. REMOVE SMOG VENTILATION SENSOR Disconnect the connector. Remove the bolt and sensor.

Installation is in the reverse order of removal (See SENSOR ).

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1. SET ON MANIFOLD GAUGE SET (See «MANIFOLD GAUGE SET»(ref-229445-S01994229252006041500000) )
2. DISCONNECT CONNECTOR FROM PRESSURE SWITCH
3. RUN ENGINE AT APPROX. 1,500 RPM
4. Magnetic Clutch Control: INSPECT PRESSURE SWITCH OPERATION Connect the positive (+) lead from the ohmmeter to terminal and the negative (-) lead to terminal 1. Check continuity between terminals when refrigerant pressure is changed (Scheme 212) If operation is not as specified, replace the pressure switch.
5. Cooling Fan Control: INSPECT PRESSURE SWITCH OPERATION Connect the positive (+) lead from the ohmmeter to terminal and the negative (-) lead to terminal 3. Check continuity between terminals when refrigerant pressure is changed (Scheme 213) If operation is not as specified, replace the pressure switch.
6. STOP ENGINE AND SET OFF MANIFOLD GAUGE SET
7. CONNECT CONNECTOR TO PRESSURE SWITCH

Scheme 214

1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 600 +/- 50 g (21.16 +/- 1.76 oz.)
2. REMOVE PRESSURE SWITCH FROM LIQUID TUBE Disconnect the connector and remove the pressure switch. Torque: 10 N.m (100 kgf.cm, 7 ft.lbf) HINT: Lock the switch mount on the tube with an open end wrench, being careful not to deform the tube, and remove the switch. At the time of installation, please refer to the following item. Lubricate a new O-ring with compressor oil and install the switch.

Installation is in the reverse order of removal (See REMOVAL ).

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1. INSPECT HEATER MAIN RELAY (Marking: HTR) CONTINUITY MAIN RELAY CONTINUITY Condition Tester connection Specified condition Constant 2 - 4 Continuity Constant 1 - 3 Continuity Apply B+ between terminals 1 and 3. 5 - 4 Continuity If continuity is not as specified, replace the relay.
2. INSPECT MAGNETIC CLUTCH RELAY (Marking: A/C COMP) CONTINUITY CLUTCH REPLAY CONTINUITY Condition Tester connection Specified condition Constant 1 - 2 Continuity Apply B+ between terminals 1 and 2. 3 - 5 Continuity If continuity is not as specified, replace the relay.
3. INSPECT No.2 COOLING FAN RELAY (Marking: FAN NO.2) CONTINUITY FAN RELAY CONTINUITY Condition Tester connection Specified condition Constant 1 - 2 Continuity Constant 3 - 4 Continuity Apply B+ between terminals 1 and 2. 3 - 5 Continuity If continuity is not as specified, replace the relay.
4. INSPECT No.3 COOLING FAN RELAY (Marking: FAN NO.3) CONTINUITY Check the relay in the same way as for "MAGNETIC CLUTCH RELAY".

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1. INSPECT CONDENSER FAN OPERATION Inspect the fan operation, as shown in «FAN OPERATION CONDITION RELAY»(ref-229445-S17895286202006041500000) . Test conditions: Ignition switch ON Blower speed control switch position "HI" Temperature control dial at "MAX. COOL" Install manifold gauge set" A/C switch ON FAN OPERATION CONDITION RELAY Condition Fan operation (Fan speed) Engine coolant temperature 91 °C (196 °F) or below Rotate (Low speed) Engine coolant temperature 100°C (212 °F) or above Rotate (High speed) Refrigerant pressure is less than 1,520 kPa (15.5 kgf.cm 2 , 220 psi) Rotate (Low speed) Refrigerant pressure is 1,520 kPa (15.5 kgf.cm 2 , 220 psi) or above Rotate (High speed) If operation is not as specified, proceed to the next inspection.
2. INSPECT CONDENSER FAN MOTOR OPERATION Disconnect the fan connector. Connect the positive (+) lead from the battery to terminal 2 and negative (-) lead to terminal 1 then check that motor operations smoothly. If operation is not as specified, replace the fan motor. If operation is as specified, check the pressure switch, cooling fan relays and engine coolant temp. switch.

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REMOVAL

1. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all coolant.
2. REMOVE THESE PARTS: Air cleaner duct Air cleaner assembly Radiator reservoir tank cap
3. DISCONNECT THESE PARTS: Upper radiator hose Reservoir hose
4. REMOVE COOLING FAN Disconnect the connectors. Remove the 6 bolts cooling fan.

Installation is in the reverse order of removal (See REMOVAL ).

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1. REMOVE THESE PARTS: No.2 register Cluster finish panel (See «REMOVAL»(ref-229437-S30123028692006041500000) )
2. REMOVE A/C CONTROL ASSEMBLY WITH RADIO Remove the 4 bolts and pull out the A/C control assembly, then disconnect the connectors.
3. REMOVE A/C CONTROL ASSEMBLY FROM RADIO Remove the 8 bolts, 2 screw and 2 brackets, then remove the A/C control assembly.

Installation is in the reverse order of removal (See REMOVAL ).

Scheme 223

1. REMOVE A/C CONTROL ASSEMBLY (See «REMOVAL»(ref-229445-S13526898402006041500000) )
2. REMOVE A/C AMPLIFIER Remove the 8 bolts, 2 screws and 2 bracket, then remove the amplifier.

Installation is in the reverse order of removal (See REMOVAL ).

Scheme 224

1. REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all coolant
3. REMOVE ECT SWITCH Disconnect the connector. Remove the ECT switch. Torque: 7.4 N.m (75 kgf.cm, 65 in.lbf) Remove the O-ring from ECT switch. HINT: At the time of installation, please refer to the following item. Lubricate a new O-ring with soapy water and install the switch.

Scheme 225

1. Using an ohmmeter, check that no continuity exists between the terminals when the coolant temperature is above 100 °C (212 °F). If continuity exists, replace the switch.
2. Using an ohmmeter, check that continuity exists between the terminals when the coolant temperature is below 91 °C (196 °F). If there no continuity exists, replace the switch.

Installation is in the reverse order of removal (See REMOVAL ).

Scheme 226

1. REMOVE GLOVE COMPARTMENT DOOR (See «REMOVAL»(ref-229437-S30123028692006041500000) )
2. REMOVE AIR REFINER FILTER Remove the cover. Pull out the air refiner filter.

Installation is in the reverse order of removal (See REMOVAL ).