2002 Air Conditioning: Removal & Installation Lexus IS I

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.

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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

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

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1. Remove Instrument Panel (See «REMOVAL & INSTALLATION»(ref-154166-S35088291742003050700000) )
2. Remove Air Duct (Duct Side) Disconnect the connector and connector clamp. Remove the screw. Release the 2 claws and pull out the air duct.
3. Disconnect Wire Harness Disconnect the connector and connector clamp. Remove the wire harness clamp and disconnect the connector.
4. Remove Blower Unit Remove the 2 bolts and bracket. Remove the bolt, screw and nut. Release the claw and 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-174966-S30065011832005041300000) ).
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: 990 - 1,210 ohms 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 3 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 Drive Belt (See «REMOVAL»(ref-174966-S22650042212005041300000) )
6. Disconnect Discharge And Suction Hoses Remove the 2 nuts and disconnect the both hoses. NOTE: Cap the open fitting immediately to keep moisture or dirt out of the system.
7. Remove P/S Pump With Pressure Feed And Return Tubes Still Connected Disconnect the P/S pump connector and P/S pump tube clamp. Disconnect the engine wire. Remove the 2 P/S pump set bolts and slide the P/S pump backward.
8. Remove Compressor Remove the bolt and P/S pump bracket. Remove the 3 bolts and compressor bracket. Disconnect the connector. Remove the nut and 2 bolts. Using a Torx socket (E10), remove the stud bolt and compressor.

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1. Remove the pressure plate. Using SST and a socket wrench, remove the shaft bolt. SST 07112-76060 Install SST on the pressure plate. SST 07112-66040 Using SST and a socket wrench, remove the pressure plate. SST 07112-66040, 07112-76060 Remove the shims from the pressure plate.
2. Remove the rotor. Remove the snap ring. 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 the stator. Disconnect the stator lead wire from the compressor. Remove the snap ring. Remove the stator.

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1. Assemble Magnetic Clutch Install the stator. Install the stator on compressor. Install the new snap ring. NOTE: The snap ring should be installed so that its beveled side faces up. Connect the stator lead wire to the compressor. Install the rotor. Install the rotor on the compressor. Install the new snap ring. NOTE: The snap ring should be installed so that its beveled side faces up. Install the pressure plate. Install the shims to the pressure plate. Install the pressure plate on the rotor. Using SST and a torque wrench, install the shaft bolt. Torque: 13.2 N.m (135 kgf.cm, 9 ft.lbf) SST 07112-76060
2. After Reassembly, Check Magnetic Clutch Clearance Set the dial indicator to the pressure plate of the magnetic clutch. Connect the magnetic clutch lead wire to the positive (+) terminal of the battery. Check the clearance between the pressure plate and rotor when connecting the negative (-) terminal to the battery. Standard clearance: 0.5 +/- 0.15 mm (0.020 +/- 0.0059 in.) If the clearance is not within the standard clearance, adjust the clearance using shims to obtain the standard clearance. Shim thickness: 0.1 mm (0.004 in.) 0.3 mm (0.012 in.) 0.5 mm (0.020in.)

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1. Install Compressor Install the compressor with the stud bolt. Torque: 26 N.m (265 kgf.cm, 19 ft.lbf) Install the 2 bolts and nut. Torque: Bolt: 52 N.m (530 kgf.cm, 38 ft.lbf) Nut: 52 N.m (530 kgf.cm, 38 ft.lbf) Connect the connector. Install the compressor bracket with the 3 bolts. Torque: bolt A: 39 N.m (400 kgf.cm, 29 ft.lbf) bolt B: 52 N.m (530 kgf.cm, 38 ft.lbf) Install the P/S pump bracket with the bolt. Torque: 52 N.m (530 kgf.cm, 38 ft.lbf)
2. Install P/S Pump Install 2 P/S pump set bolt. Torque: 58 N.m (590 kgf.cm, 43 ft.lbf) Connect the engine wire. Connect the P/S pump connector and wire harness clamp.
3. Connect Discharge And Suction Hoses
4. Connect the both hoses with 2 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 hoses.
5. Install Drive Belt (See «INSTALLATION»(ref-174966-S21663451162005041300000) )
6. Inspect Drive Belt Tension (See «DRIVE BELT»(ref-174966-S22981545182005041300000) )
7. Connect Negative (-) Terminal Cable To Battery
8. Evacuate Air From Refrigeration System And Charge System With Refrigerant Specified amount: 600 +/- 50 g (21.16 +/- 1.76 oz.)
9. 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.
10. Inspect A/C Operation

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

Installation Is In The Reverse Order Of Removal (See REMOVAL ).

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1. Remove Blower Motor Remove the wire harness clamp and disconnect the connector. Remove the 3 screws and blower motor.
2. Inspect Blower Motor Operation Connect the positive (+) lead from the battery to terminal 2 and negative (-) lead to terminal 1, then check that the motor operations smoothly. If operation is not as specified, replace the blower motor.
3. Install Blower Motor Install the blower motor with the 3 screws. Connect the connector and wire harness clamp.

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1. Remove Glove Compartment Door (See REMOVE GLOVE COMPARTMENT DOOR )
2. Remove Blower Motor Control Relay Disconnect the connectors. Remove the screw and blower motor control relay.
3. Inspect Blower Motor Control Circuit Inspect the wire harness side connector from the back side, as shown in the chart. Test conditions: Turn ignition switch to ON Operate blower motor (High blower speed) If resistance is not as specified, replace the blower motor control relay.
4. Install Blower Motor Control Relay Install the blower motor control relay with the screw. Connect the connectors.
5. Install Glove Compartment Door (SeeINSTALL GLOVE COMPARTMENT DOOR ).

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1. Remove Glove Compartment Door (See «REMOVAL & INSTALLATION»(ref-154166-S35088291742003050700000) )
2. Remove Bracket Disconnect The Wire Harness Clamp. Remove The 2 Bolts And Bracket.
3. Remove Air Inlet Servomotor Disconnect the connector. Remove the 3 screws and servomotor.
4. Inspect Air Inlet Servomotor Operation Connect the positive (+) lead from the battery to terminal 7 and negative (-) lead to terminal 6, then check that the arm turns to "FRESH" side smoothly. Connect the positive (+) lead from the battery to terminal 6 and negative (-) lead to terminal 7, then check that the arm turns to "RECIRC" side smoothly. If operations are not as specified, replace the servomotor.
5. Inspect Position Sensor Resistance Measure resistance between terminals at servomotor arm each position as shown in the chart. If resistance is not as specified, replace the servomotor.
6. Install Air Inlet Servomotor Install the servomotor with the 3 screws. Connect the connector.
7. Install Bracket Install the bracket with 2 bolts. Connect the wire harness clamp.
8. Install Glove Compartment Door (See INSTALL GLOVE COMPARTMENT DOOR )

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1. Remove Instrument Panel (See «REMOVAL & INSTALLATION»(ref-154166-S35088291742003050700000) )
2. Remove Air Duct Disconnect the connector clamp. Remove the 3 screws and air duct.
3. Remove Air Outlet Servomotor Disconnect the connector. Remove the 2 screws and servomotor.
4. Inspect Air Outlet Servomotor Operation Connect the positive (+) lead from the battery to terminal 7 and negative (-) lead to terminal 6, then check that the arm turns to "FACE" side smoothly. Connect the positive (+) lead from the battery to terminal 6 and negative (-) lead to terminal 7, then check that the arm turns to "DEF" side smoothly. If operations are not as specified, replace the servomotor.
5. Inspect Position Sensor Resistance Measure resistance between terminals at servomotor arm each position as shown in the chart. If resistance is not as specified, replace the servomotor.
6. Install Air Outlet Servomotor Install the servomotor with the 2 screws. Connect the connector.
7. Install Air Duct Install the air duct with the 3 screws. Connect the connector clamp.
8. Install Instrument Panel (See «REMOVAL & INSTALLATION»(ref-154166-S35088291742003050700000) )

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1. Remove Solar Sensor Using a screwdriver, pull out the sensor, then disconnect the connector. HINT: Tape the screwdriver tip before use.
2. Inspect Solar Sensor Continuity Cover the sensor with a cloth, check that the no continuity exists between terminals. If continuity exists, replace the sensor. Remove the cloth from the sensor and subject the sensor to electric light, check that continuity exists between terminals. If no continuity exists, replace the sensor.
3. Install Solar Sensor Connect the connector and install the solar sensor.

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1. Remove Lower Finish Panel Remove the 3 screws. Release the 3 claws and pull out the lower finish panel.
2. Remove Room Temperature Sensor Disconnect the connector and aspirator hose. Release the 2 claws and pull out the sensor.
3. Inspect Room Temperature Sensor Resistance Measure resistance between terminals at each temperature as shown in the chart. If resistance is not as specified, replace the sensor.
4. Install Room Temperature Sensor Install the sensor and fit the 2 claws. Connect the aspirator hose and connector.
5. Install Lower Finish Panel Install the lower finish panel and fit the 3 claws. Install the 3 screws.

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1. Remove Ambient Temperature Sensor Disconnect the connector. Using a clip remover, pull out the sensor from bumper reinforcement.
2. Inspect Ambient Temperature Sensor Resistance Measure resistance between terminals at each temperature as shown in the chart. If resistance is not as specified, replace the sensor.
3. Install Ambient Temperature Sensor Push the sensor in bumper reinforcement. Connect the connector.

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1. Remove Lower Finish Panel (See «REMOVAL & INSTALLATION»(ref-154166-S35088291742003050700000) )
2. Remove Evaporator Temperature Sensor Disconnect the connector. 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.
3. Inspect Evaporator Temperature Sensor Resistance Place the sensor in cold water, and while changing the temperature of the water, measure resistance at the connector and at the same time, measure temperature of the water with a thermometer. Compare the 2 readings on the chart. If resistance value is not as specified, replace the sensor.
4. Install Evaporator Temperature Sensor Install the sensor in bracket plate and 2 claws. Push in the sensor with the bracket plate. Connect the connector.
5. Install Lower Finish Panel (See INSTALL LOWER FINISH PANEL )

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1. Set On Manifold Gauge Set (See «MANIFOLD GAUGE SET»(ref-174966-S03291344402005041300000) )
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 4 and the negative (-) lead to terminal 1. Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. 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 2 and the negative (-) lead to terminal 3. Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. 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

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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 +/- 1.76 oz.)
2. Remove Radiator Grille (See REMOVE RADIATOR GRILLE )
3. 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. Remove Front Door Scuff Plate LH (See REMOVE FRONT DOOR SCUFF PLATE LH )
2. Remove Cowl Side Trim Board LH (See REMOVE COWL SIDE TRIM BOARD LH )
3. Remove Heater Main Relay Disconnect the connectors. Remove the 2 passenger side junction block set nuts. Remove the heater main relay from passenger side junction block.
4. Inspect Heater Main Relay Continuity If continuity is not as specified, replace the relay.
5. Install Heater Main Relay Install the heater main relay to passenger side junction block. Install the passenger side junction block set nuts. Connect the connectors.
6. Install Cowl Side Trim Board LH (See REMOVE COWL SIDE TRIM BOARD LH )
7. Install Front Door Scuff Plate LH (See REMOVE FRONT DOOR SCUFF PLATE LH )

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1. Remove Magnetic Clutch Relay From Relay Block No. 3
2. Inspect Magnetic Clutch Relay (Marking: A.C Comp) Continuity If continuity is not as specified, replace the relay.

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1. Remove No. 2 Cooling Fan Relay From Relay Block No. 3
2. Remove No. 3 Cooling Fan Relay From Relay Block No. 3
3. Inspect No. 2 Cooling Fan Relay (Marking: Fan No. 2) 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 the chart below. Test conditions: Ignition switch ON Blower speed control switch position "HI" Temperature control dial at "MAX. COOL" position Install manifold gauge set A/C switch ON If operation is not as specified, proceed to the next inspection.
2. Inspect Condenser Fan Motor Operation Disconnect the fan connector. Connect battery and ammeter. Check that the fan rotates smoothly, and then check the reading on the ammeter. Specified amperage: 8.5 - 11.5 A or 20 °C (68 °F) 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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1. Drain Engine Coolant From Radiator HINT: It is not necessary to drain out all coolant.
2. Remove Air Cleaner Inlet
3. Remove Air Cleaner And MAF Meter Assembly
4. Remove Cooling Fan Disconnect the upper radiator hose from the radiator. Disconnect the ECM outlet duct from the ECM box. Disconnect the wire for cooling fan from the clamp on the cooling fan. Disconnect the 2 cooling fan connector. Disconnect the radiator reservoir hose from the radiator. Remove the 6 bolts and cooling fan.

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1. Remove Fans Remove the nut and fan. Remove the 2 fans.
2. Remove Fan Motors Disconnect the wires and connector holders from the fan shroud. Remove the 3 screws and fan motor. Remove the 2 fan motors.

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1. Install Fan Motors Install the fan motor with the 3 screws. Install the 2 fan motors. Install the wires and connector holders to the fan shroud as shown in the illustration.
2. Install Fans
3. Install the fan with the nut. Install the 2 fans.

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1. Install Cooling Fan Install the cooling fan with the 6 bolts. Torque: 5.0 N.m (50 kgf.cm, 44 in.lbf) Connect the upper radiator hose to the radiator. Connect the ECM outlet duct to the ECM box. Connect the wire for cooling fan to clamp on the cooling fan. Connect the 2 cooling fan connectors. Connect the radiator reservoir hose to the radiator.
2. Install Air Cleaner And MAF Meter Assembly
3. Install Air Cleaner Inlet
4. Fill With Engine Coolant
5. Start Engine And Check For Coolant Leaks

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1. Remove A/C Control Assembly (See «REMOVAL»(ref-174966-S10479909992005041300000) )
2. Inspect A/C Control Assembly Circuit Disconnect the connector from the A/C control assembly and inspect the connector on the wire harness side, as shown in the chart below. Test condition: Turn ignition switch ON If the circuit is not as specified, inspect the circuit connected to other parts. If the circuit is as specified, proceed to «INSPECTION»(ref-174966-S13998629622005041300000) . Connect the connector to amplifier and inspect the wire harness side connector from the back side, as shown in the chart. Test conditions: Running engine at idle speed Blower speed control dial at "HI" position Temperature control dial at "MAX. COOL" position A/C switch ON If the circuit is not as specified, proceed to «INSPECTION»(ref-174966-S13998629622005041300000) .
3. Install A/C Control Assembly (See «INSTALLATION»(ref-174966-S10763225542005041300000) )

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1. Remove Center Cluster Finish Panel (See REMOVE CENTER CLUSTER FINISH PANEL )
2. Remove Lower Center Cluster Finish Panel (See REMOVE LOWER CENTER CLUSTER FINISH PANEL )
3. Remove A/C Control Assembly Remove the 4 bolts and pull out the A/C control assembly with radio assembly, then disconnect the connectors. Remove the 12 screws and 2 brackets. Separate the A/C control assembly and radio assembly.

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1. Remove A/C Amplifier Remove the 4 screws. Using a screwdriver, release the 4 claws and pull out the A/C amplifier. HINT: Tape the screwdriver tip before use. Release the connector lock and pull out the flat harness. NOTE: Pull the lock of the connector securely toward you and pull off the flexible flat cable.
2. Remove Bulbs Using a screwdriver, turn the bulbs to the left and pull out the bulbs.
3. Remove P/C Board Remove the 4 screws and P/C board. NOTE: Do not let any oil, dirt or foreign object on the connecting part of the P/C board. When holding the P/C board by hand, hold it at the edge and do not touch the soldered part and connecting part. Do not apply unnecessary force to the jumper lead. Do not let the accumulated static electricity in an operator apply to the electronic components. Do not tumble the LED as this soldered to the P/C board at right angles.
4. Remove Dial Knobs Remove the 6 screws and dial knobs. NOTE: Do not let any oil, dirt or foreign object attach on the connecting part of the connector. Do not deform the contact. Be careful not to drop the contact.
5. Remove Knob Sets Pull out the knob sets. NOTE: Do not let any oil, dirt or foreign object attach on the rubber contact part.
6. Remove Lens

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1. Inspect Indictor Operation Connect the positive (+) lead from the battery to terminal 4 and negative (-) lead to each terminal, then check that the indicator lights up as shown in the chart. If operation is not as specified, replace the P/C board.
2. Inspect Indicator Dimming Operation Perform each indicator light up (See step 1). Connect the positive (+) lead from the battery to terminal 1 and check that the each indicator dims. If the operation is not as specified, replace the P/C board. If the operation is as specified, replace the A/C amplifier.
3. Inspect Bulb Operation Apply the tester as shown in the illustration to the test for continuity. If continuity exists, replace the P/C board. If on continuity exists, replace the bulb.
4. Inspect Switch Operation Check the continuity exists between terminals while the switch is pressed. If operations is not as specified, replace the P/C board. If operations is as specified, check the wire harness or replace the A/C amplifier.

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

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1. Remove Engine Under Cover
2. Drain Engine Coolant From Radiator HINT: It is not necessary to drain out all coolant
3. Remove Engine Coolant Temperature Switch Disconnect the connector. Remove the engine coolant temperature switch. Remove the O-ring from the switch.
4. Inspect Engine Coolant Temperature Switch Using an ohmmeter, check that no continuity exists between the terminals when the coolant temperature i' above 100 °C (212 °F). If continuity exists, replace the switch. 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.
5. Install Engine Coolant Temperature Switch Install the new O-ring to the switch. Install the engine coolant temperature switch. Torque: 7.4 N.m (75 kgf.cm, 65 in.lbf)
6. Fill With Engine Coolant To Radiator
7. Install Engine Under Cover

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1. Remove Glove Compartment Door (See REMOVE GLOVE COMPARTMENT DOOR )
2. Remove Air Refiner Filter Remove the cover. Pull out the air refiner filter.

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