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Air Conditioning: Overhaul Lexus IS II

Automatic HVAC System 31 illustrations ~1814 words

DISASSEMBLY

  1. REMOVE MAGNETIC CLUTCH ASSEMBLY (See «REMOVAL»(ref-235579-S35142441472006062400000) )

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Scheme 274: INSPECTION
Scheme 274: INSPECTION

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  1. INSPECT A/C COMPRESSOR Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition E8-1 (MG+) - A-1 Always Below 1 ohms E8-1 (MG+) - Body ground Always 10 kohms or higher If the resistance is not as specified, replace the A/C compressor.
  2. INSPECT MAGNETIC CLUTCH Measure the resistance of the connector. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition A-1 - Body ground Always 3.4 to 3.8 ohms If the resistance is not as specified, replace the magnetic clutch. When connector terminal A1 is connected to the positive (+) battery terminal, check that the following occurs: 1) the magnetic clutch's operating sound can be heard, and 2) the magnetic clutch's hub and rotor lock.
  3. INSPECT A/C COMPRESSOR (LOCK SENSOR) Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition E8-2 (SSR+) - E8-5 (SSR-) 160 to 320 ohms If the resistance is not as specified, replace the A/C compressor.
  4. INSPECT A/C COMPRESSOR (SOLENOID) Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition E8-3 (SOL+) - E8-6 (SOL-) 20°C (68°F) 10 to 11 ohms If the resistance is not as specified, replace the A/C compressor.

REASSEMBLY

  1. INSTALL MAGNETIC CLUTCH ASSEMBLY (See «REASSEMBLY»(ref-235579-S26333579972006062400000) )
  2. INSPECT MAGNETIC CLUTCH CLEARANCE (See «REASSEMBLY»(ref-235579-S26333579972006062400000) )
  3. ADJUST COMPRESSOR OIL (See «REASSEMBLY»(ref-235579-S26333579972006062400000) )

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Scheme 278: INSTALLATION
Scheme 278: INSTALLATION

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  1. TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH Using an E8 "torx " socket, install the compressor with the stud bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Temporarily tighten the cooler compressor with magnetic clutch assembly with the 2 bolts and nut.
  2. INSTALL DISCHARGE HOSE SUB-ASSEMBLY (See «INSTALLATION»(ref-235579-S15215420202006062400000) )
  3. INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE (See «INSTALLATION»(ref-235579-S15215420202006062400000) )
  4. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY Install a new oil filter bracket gasket and the oil filter bracket sub-assembly with the 2 nuts and bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Connect the connector and install the wire harness with the 2 clamps.
  5. INSTALL OIL FILTER BRACKET Install the oil filter bracket with the bolt and nut. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) NOTE: Tighten the bolts in the order shown in the illustration to install the compressor.
  6. FULLY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH Install the compressor with the bolts and nut. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) NOTE: Tighten the bolts in the order shown in the illustration to install the compressor.
  7. INSTALL V-RIBBED BELT (See «INSTALLATION»(ref-235451-S09883656572006062200000) )
  8. INSTALL UNDER ENGINE COVER
  9. CHARGE REFRIGERANT (See «REPLACEMENT»(ref-235579-S02745364222006062400000) )
  10. WARM UP ENGINE (See «REPLACEMENT»(ref-235579-S02745364222006062400000) )
  11. CHECK FOR LEAKAGE OF REFRIGERANT (See «REPLACEMENT»(ref-235579-S02745364222006062400000) )
  12. INSTALL NO. 1 INLET AIR CLEANER (See «INSTALLATION»(ref-235451-S29453453712006062200000) )
  13. INSTALL V-BANK COVER SUB-ASSEMBLY (See «INSTALLATION»(ref-235451-S29453453712006062200000) )
  14. INSTALL COOL AIR INTAKE DUCT SEAL (See «INSTALLATION»(ref-235451-S29453453712006062200000) )

Scheme 284

Scheme 284: COMPONENTS
Scheme 284: COMPONENTS

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Scheme 287: REMOVAL
Scheme 287: REMOVAL

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  1. REMOVE COOL AIR INTAKE DUCT SEAL (See «REMOVAL»(ref-235451-S13841571552006062200000) )
  2. REMOVE SIDE ENGINE ROOM COVER LH (See «REMOVAL»(ref-235451-S13841571552006062200000) )
  3. REMOVE SIDE ENGINE ROOM COVER RH (See «REMOVAL»(ref-235451-S13841571552006062200000) )
  4. REMOVE V-BANK COVER SUB-ASSEMBLY (See «REMOVAL»(ref-235451-S13841571552006062200000) )
  5. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM Start up the engine. Turn the A/C switch on. Operate the cooler compressor at an engine rpm of approximately 1,000 for 5 to 6 minutes to circulate the refrigerant and collect compressor oil remaining in each component into the cooler compressor as much as possible. Stop the engine. Using SST, let the refrigerant gas out. SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
  6. REMOVE NO. 1 INLET AIR CLEANER (See «REMOVAL»(ref-235451-S13841571552006062200000) )
  7. REMOVE UNDER ENGINE COVER
  8. REMOVE FRONT BUMPER ASSEMBLY (See «REMOVAL»(ref-235598-S24774280692006062400000) )
  9. REMOVE FRONT BUMPER ENERGY ABSORBER
  10. REMOVE RADIATOR SUPPORT OPENING COVER (See «REMOVAL»(ref-235453-S00754768742006062200000) )
  11. REMOVE MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System) (See «REMOVAL»(ref-235581-S09002312972006062400000) )
  12. REMOVE HOOD LOCK CONTROL CABLE COVER (See «REMOVAL»(ref-235453-S00754768742006062200000) )
  13. DISCONNECT HOOD LOCK ASSEMBLY (See «REMOVAL»(ref-235453-S00754768742006062200000) )
  14. REMOVE RADIATOR SUPPORT UPPER (See «REMOVAL»(ref-235453-S00754768742006062200000) )
  15. DISCONNECT LIQUID TUBE SUB-ASSEMBLY Remove the 2 bolts and disconnect the liquid tube sub-assembly from the cooler condenser assembly. Remove the O-ring from the liquid tube subassembly. NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
  16. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY Remove the bolt and disconnect the discharge hose sub-assembly from the cooler condenser assembly. Remove the O-ring from the discharge hose subassembly. NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
  17. REMOVE COOLER CONDENSER ASSEMBLY Remove the 4 bolts and cooler condenser assembly.
  18. REMOVE COOLER DRYER Using a straight hexagon wrench 14 mm, remove the cap from the modulator. Using pliers, remove the cooler dryer.

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Scheme 292: INSTALLATION
Scheme 292: INSTALLATION

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  1. INSTALL COOLER DRYER Using pliers, install the cooler dryer to the modulator. Sufficiently apply compressor oil to an O-ring and cap fitting surface. Compressor oil: ND-OIL 8 or equivalent Using a straight hexagon wrench 14 mm, install the cap to the cooler condenser core. Torque: 2.9 N*m (30 kgf*cm, 26 in.*lbf)
  2. INSTALL COOLER CONDENSER ASSEMBLY Install the cooler condenser assembly with the 4 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) HINT: If the condenser is replaced with a new one, add compressor oil to the new condenser. Capacity: 40 cc (1.4 fl. oz.) Compressor oil: ND-8 or equivalent
  3. INSTALL DISCHARGE HOSE SUB-ASSEMBLY Remove the attached vinyl tape from the hose and the connecting part of the cooler condenser assembly. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the hose joint. Compressor oil: ND-OIL 8 or equivalent Install the O-ring on the discharge hose subassembly. Install the discharge hose sub-assembly on the cooler condenser assembly with the bolt. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  4. INSTALL LIQUID TUBE SUB-ASSEMBLY Remove the attached vinyl tape from the pipe and the connecting part of the cooler condenser assembly. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the pipe joint. Compressor oil: ND-OIL 8 or equivalent Install the O-ring on the liquid tube sub-assembly. Install the liquid tube sub-assembly on the cooler condenser assembly with the 2 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  5. INSTALL RADIATOR SUPPORT UPPER (See «INSTALLATION»(ref-235453-S29810577722006062200000) )
  6. INSTALL HOOD LOCK ASSEMBLY (See «INSTALLATION»(ref-235453-S29810577722006062200000) )
  7. INSTALL HOOD LOCK CONTROL CABLE COVER (See «INSTALLATION»(ref-235453-S29810577722006062200000) )
  8. INSTALL MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System) (See «INSTALLATION»(ref-235581-S22372426352006062400000) )
  9. INSTALL RADIATOR SUPPORT OPENING COVER (See «INSTALLATION»(ref-235453-S29810577722006062200000) )
  10. INSTALL FRONT BUMPER ENERGY ABSORBER
  11. INSTALL FRONT BUMPER ASSEMBLY
  12. INSTALL UNDER ENGINE COVER
  13. INSTALL NO. 1 INLET AIR CLEANER (See «INSTALLATION»(ref-235451-S29453453712006062200000) )
  14. CHARGE REFRIGERANT (See «REPLACEMENT»(ref-235579-S02745364222006062400000) )
  15. WARM UP ENGINE (See «REPLACEMENT»(ref-235579-S02745364222006062400000) )
  16. CHECK FOR LEAKAGE OF REFRIGERANT (See «REPLACEMENT»(ref-235579-S02745364222006062400000) )
  17. INSTALL V-BANK COVER SUB-ASSEMBLY (See «INSTALLATION»(ref-235451-S29453453712006062200000) )
  18. INSTALL SIDE ENGINE ROOM COVER LH (See «INSTALLATION»(ref-235451-S29453453712006062200000) )
  19. INSTALL SIDE ENGINE ROOM COVER RH (See «INSTALLATION»(ref-235451-S29453453712006062200000) )
  20. INSTALL COOL AIR INTAKE DUCT SEAL (See «INSTALLATION»(ref-235451-S29453453712006062200000) )

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Scheme 298: COMPONENTS
Scheme 298: COMPONENTS

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Scheme 299: REMOVAL
Scheme 299: REMOVAL
  1. DISCONNECT CABLE FROM NEGATIVE BATTERY CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. (See «PRECAUTION»(ref-235542-S10058841152006062400000) )
  2. REMOVE FRONT DOOR SCUFF PLATE LH (w/o Illumination) (See «REMOVAL»(ref-235599-S10274364092006062400000) )
  3. REMOVE FRONT DOOR SCUFF PLATE LH (w/ Illumination) (See «REMOVAL»(ref-235599-S10274364092006062400000) )
  4. REMOVE FRONT DOOR OPENING TRIM COVER LH (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
  5. REMOVE SIDE INSTRUMENT PANEL LH (See «REMOVAL»(ref-235591-S20751754672006062400000) )
  6. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
  7. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
  8. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY (See «REMOVAL»(ref-235542-S32764164272006062400000) )
  9. REMOVE ROOM TEMPERATURE SENSOR Disconnect the connector and air hose. Detach the claw and remove the sensor.

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Scheme 300: INSPECTION
Scheme 300: INSPECTION
  1. INSPECT ROOM TEMPERATURE SENSOR Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition J38-1 - J38-2 10°C (50°F) 3.00 to 3.73 kohms J38-1 - J38-2 15°C (59°F) 2.45 to 2.88 kohms J38-1 - J38-2 20°C (68°F) 1.95 to 2.30 kohms J38-1 - J38-2 15°C (77°F) 1.60 to 1.80 kohms J38-1 - J38-2 30°C (86°F) 1.28 to 1.47 kohms J38-1 - J38-2 35°C (95°F) 1.00 to 1.22 kohms J38-1 - J38-2 40°C (104°F) 0.80 to 1.00 kohms J38-1 - J38-2 45°C (113°F) 0.65 to 0.85 kohms J38-1 - J38-2 50°C (122°F) 0.50 to 0.70 kohms J38-1 - J38-2 55°C (131°F) 0.44 to 0.60 kohms J38-1 - J38-2 60°C (140°F) 0.36 to 0.50 kohms NOTE: Hold the sensor only by its connector. Touching the sensor may change the resistance value. When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph). If the resistance is not as specified, replace the room temperature sensor.

Scheme 301

Scheme 301: INSTALLATION
Scheme 301: INSTALLATION
  1. INSTALL ROOM TEMPERATURE SENSOR Install the sensor with the claw. Connect the connector and attach the air hose.
  2. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY (See «INSTALLATION»(ref-235542-S26103287292006062400000) )
  3. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
  4. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
  5. INSTALL SIDE INSTRUMENT PANEL LH (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
  6. INSTALL FRONT DOOR OPENING TRIM COVER LH (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
  7. INSTALL FRONT DOOR SCUFF PLATE LH (w/o Illumination) (See «INSTALLATION»(ref-235599-S41342360772006062400000) )
  8. REMOVE FRONT DOOR SCUFF PLATE LH (w/ Illumination) (See «INSTALLATION»(ref-235599-S41342360772006062400000) )
  9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
  10. PERFORM INITIALIZATION NOTE: Some systems need initialization after reconnecting the cable to the negative battery terminal (See «INITIALIZATION»(ref-235541-S32349848442006062400000) )
  11. INSPECT SRS WARNING LIGHT (See «DIAGNOSIS SYSTEM»(ref-235542-S25406180262006062400000) )

Scheme 302

Scheme 302: COMPONENTS
Scheme 302: COMPONENTS

Scheme 303

Scheme 303: REMOVAL
Scheme 303: REMOVAL
  1. REMOVE COOL AIR INTAKE DUCT SEAL (See «REMOVAL»(ref-235598-S24774280692006062400000) )
  2. REMOVE FRONT BUMPER ASSEMBLY (See «REMOVAL»(ref-235598-S24774280692006062400000) )
  3. REMOVE AMBIENT TEMPERATURE SENSOR Disconnect the connector and detach the clamp. Remove the ambient temperature sensor.

Scheme 304

Scheme 304: INSPECTION
Scheme 304: INSPECTION
  1. INSPECT AMBIENT TEMPERATURE SENSOR Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition B5-1 - B5-2 10°C (50°F) 3.00 to 3.73 kohms B5-1 - B5-2 15°C (59°F) 2.45 to 2.88 kohms B5-1 - B5-2 20°C (68°F) 1.95 to 2.30 kohms B5-1 - B5-2 25°C (77°F) 1.60 to 1.80 kohms B5-1 - B5-2 30°C (86°F) 1.28 to 1.47 kohms B5-1 - B5-2 35°C (95°F) 1.00 to 1.22 kohms B5-1 - B5-2 40°C (104°F) 0.80 to 1.00 kohms B5-1 - B5-2 45°C (113°F) 0.65 to 0.85 kohms B5-1 - B5-2 50°C (122°F) 0.50 to 0.70 kohms B5-1 - B5-2 55°C (131°F) 0.44 to 0.60 kohms B5-1 - B5-2 60°C (140°F) 0.36 to 0.50 kohms NOTE: Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph). If the resistance is not as specified, replace the ambient temperature sensor.

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