Air Conditioning System: Removal & Installation Lexus LX J100 рестайлинг

REMOVE DRIVE BELT

Loosen the drive belt tension by turning the drive belt tensioner counterclockwise, and remove the drive belt.

Scheme 146

INSTALLATION

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

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Scheme 148

1. CONNECT CHARGING HOSE 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 VALVES 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 149

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 LINE

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: Do not tighten the connections more than specified. REFRIGERANT LINE TORQUE SPECIFICATIONS Part Tightened N.m kgf.cm ft.lbf Compressor at Discharge hose 10 100 7 Compressor at Suction hose 10 100 7 Condenser at Discharge hose 10 10 7 Condenser at Liquid tube 10 100 7 Rear cooling unit at Liquid and suction tubes 10 100 7 Liquid line Nut 14 140 10 Liquid line Bolt 10 100 7 Discharge line Nut 22 225 16 Suction line Nut 32 330 24 Suction line Bolt 10 100 7
4. EVACUATE AIR FROM REFRIGERATION SYSTEM AND CHARGE SYSTEM WITH REFRIGERANT Specified amount: 1,050 +/- 50 g (37.03 +/- 1.76 oz.)
5. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leaks of refrigerant
6. INSPECT AIR CONDITIONING OPERATION

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1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, first evacuate air from refrigeration system. Then, charge the system with the refrigerant and inspect for leaks of the refrigerant. Specified amount: 1,050 +/- 50 g (37.03 +/- 1.76 oz.)
2. DISCONNECT LIQUID AND SUCTION TUBES Using SST, remove the 2 piping clamps. SST 09870-00025 (Liquid tube) 09870-00015 (Suction tube) Insert SST to piping clamp. HINT: Confirm the direction of the piping clamp claw and SST referring to (Scheme 152) on the caution label. Push down SST and release the clamp lock. NOTE: Be careful not to deform the tubes when pushing SST. Pull SST slightly and push the release lever, then remove the piping clamp with SST. Remove the piping clamp from SST. Disconnect the both tubes. NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system. HINT: At the time of installation: Lubricate 4 new O-rings with compressor oil and install them to the tubes. After connection, check the fitting for claw of the piping clamp.
3. REMOVE INSTRUMENT PANEL AND REINFORCEMENT (See «REMOVAL»(ref-215758-S06668151382006011900000) )
4. REMOVE ANTENNA RELAY Disconnect the connector. Remove the 2 screws and antenna relay.
5. REMOVE COOLING UNIT Disconnect the connector. Remove the 4 screws, 2 nuts and cooling unit.

Scheme 157

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Scheme 159

1. REMOVE EVAPORATOR Disconnect the connector clamp. Remove the 8 screws and No. 1 cooler cover. Pull out the evaporator HINT: At the time of reassembly, if evaporator is replaced, add compressor oil to the evaporator. Add: 40 cc (1.4 fl.oz.) Compressor oil: ND-OIL 8 or equivalent Pull out the air refiner filter.
2. PULL OUT EVAPORATOR TEMPERATURE SENSOR FROM EVAPORATOR
3. REMOVE EXPANSION VALVE Remove the grommet. Pry out the packing. HINT: At the time of reassembly, do not reuse the packing. Using a hexagon wrench (5.0 mm, 0.20 in.), remove the 2 bolts and separate the expansion valve, tube and evaporator. Torque: 3.4 N.m (35 kgf.cm, 30 in.lbf) NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system. HINT: At the time of reassembly, lubricate 4 new O-rings with compressor oil and install them in the tube.
4. REMOVE DRAIN HOSE

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

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Scheme 162

1. INSPECT EXPANSION VALVE Check amount of gas during refrigeration cycle. Set on manifold gauge set. Start the engine. Operate the A/C system. Inspect the expansion valve. Run the engine at 1,500 RPM for at least 5 minutes. Check the high pressure reading is 1.37 -1.57 MPa (14-16 kgf/cm 2 , 199 - 288 psi). Check the low pressure reading. If the low pressure reading is 0 kPa (0 kgf/cm 2 , 0 psi), replace the expansion valve.
2. REMOVE REAR DOOR SCUFF PLATE RH
3. REMOVE REAR FLOOR MAT SUPPORT PLATE
4. REMOVE QUARTER TRIM PANEL RH
5. INSPECT THERMISTOR RESISTANCE Disconnect the connector. Measure resistance between terminal 3 and 4. Standard resistance: Approx. 1.5 kohms at 25°C (77°F) If resistance is not as specified, proceed "INSPECTION" on «INSPECTION»(ref-215765-S36322766802006081800000) .
6. INSPECT MAGNETIC VALVE CONTINUITY Disconnect the connector. Check the continuity exists between terminal 1 and 2. If resistance is not as specified, proceed "INSPECTION" on «INSPECTION»(ref-215765-S36322766802006081800000) .
7. CHECK FOR LEAKAGE OF REFRIGERANT Remove the power transistor. Using a gas leak detector, check for leaks of refrigerant. If there is a leakage, check the evaporator or tightening torque at the joints.

Scheme 163

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Scheme 168

1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, first evacuate air from refrigeration system. Then, charge the system with the refrigerant and inspect for leaks of the refrigerant. Specified amount: 1,050 +/- 50 g (37.04 +/- 1.76 oz.)
2. DISCONNECT LIQUID AND SUCTION TUBES Remove the bolt and slide the plate, then disconnect 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, lubricate 2 new O-rings with compressor oil and install them to the tubes.
3. REMOVE REAR DOOR SCUFF PLATE RH
4. REMOVE REAR FLOOR MAT SUPPORT PLATE
5. REMOVE ROOF HEADLINING REAR TRIM
6. REMOVE QUARTER TRIM PANEL RH
7. REMOVE ROOF SIDE INNER UPPER GARNISH (See «REMOVAL»(ref-242607-S41535649822006081600000) )
8. REMOVE NO. 1 COOLER AIR DUCT Remove the 3 roof headlining set clips. Remove the 5 clips and the No. 1 cooler air duct.
9. REMOVE REAR COOLING UNIT Disconnect the connectors. Remove the 3 bolts and the rear cooling unit.

Scheme 169

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Scheme 177

1. REMOVE A/C AMPLIFIER Remove the 2 screws and the A/C amplifier.
2. REMOVE POWER TRANSISTOR Disconnect the connector. Remove the 2 screws and the power transistor.
3. REMOVE BLOWER CASE Remove the wire harness. Remove the 11 screws, 3 holding springs and separate the cooling unit cases. Disconnect the connector. Remove the blower case.
4. REMOVE BLOWER MOTOR Remove the 3 screws and the blower motor.
5. REMOVE EVAPORATOR Disconnect the 2 connector clamps. Remove the 10 screws and the 2 holding springs, and separate the cooling unit cases. Pull out the thermistor from the evaporator. Remove the screw and the piping clamp. Loosen the 2 nuts and remove the tube and accessory. Torque: Liquid line: 14 N.m (140 kgf.cm, 10 ft.lbf) Suction line: 32 N.m (330 kgf.cm, 24 ft.lbf) NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system. HINT: At the time of reassembly, lubricate 2 new O-rings with compressor oil and install them in the tubes. Remove the evaporator. HINT: At the time of reassembly, if evaporator was replaced, add compressor oil to the new evaporator. Add 40 cc: (1.4 fl.oz.) Compressor oil: ND-OIL 8 or equivalent
6. REMOVE EXPANSION VALVE Using a hexagon wrench (5.0 mm, 0.20 in.), remove the 2 bolts and separate the expansion valve and evaporator. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) HINT: At the time of reassembly, lubricate 4 new O-rings with compressor oil and install them in the tubes.

Scheme 178

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Scheme 181

1. INSPECT BLOWER MOTOR OPERATION Connect battery positive (+) lead to terminal 1 and battery negative (-) lead to terminal 2, then check that the motor rotates smoothly. If the motor rotates smoothly, check the wire harness, otherwise, replace the blower motor.
2. INSPECT THERMISTOR RESISTANCE Place the thermistor in cold water. Measure resistance of the thermistor as the water temperature increases. Compare the readings with the chart. If the values meet the specifications, check the wire harness. Otherwise, replace the thermistor.
3. INSPECT MAGNETIC VALVE OPERATION Check the air passage through the valve, with and without the battery positive voltage applied, between terminals as shown in the chart. MAGNETIC VALVE CONNECTOR TERMINAL CONNECTION CONDITION Condition Air passage Apply B+ between terminals Free passage Not apply B+ between terminals No passage Otherwise, replace the magnetic valve with the expansion valve. If operation is as specified, check the wire harness.
4. INSPECT EVAPORATOR Check the evaporator fins for blockage. If the fins are clogged, remove them with compressed air. NOTE: Never use water to clean the evaporator. Check the fitting for cracks or scratches. If necessary, repair or replace.

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

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Scheme 186

1. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all coolant.
2. DISCONNECT WATER HOSES FROM HEATER RADIATOR PIPES Using pliers, grip the claws of the hose clip and slide the clip along the hose. Disconnect the water hoses from the heater radiator pipes. HINT: At the time of installation, refer to the following items. Push the water hose onto the heater radiator pipe to the second ridge on the pipe. Install a hose clip in the position (Scheme 184)
3. REMOVE INSTRUMENT PANEL AND REINFORCEMENT (See «REMOVAL»(ref-215758-S06668151382006011900000) )
4. REMOVE FRONT COOLING UNIT (See «REMOVAL»(ref-215765-S24117320832006081800000) )
5. REMOVE HEATER UNIT Remove the lower defroster nozzle. Disconnect the connector. Remove the 4 nuts and heater unit.

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Scheme 191

1. REMOVE HEATER RADIATOR Pry out the packing. Remove the screw and the bracket. Remove the screw and the clamp. Pull out the heater radiator.
2. REMOVE AIR OUTLET SERVOMOTOR Remove the 3 screws and the air outlet servomotor.
3. REMOVE AIR MIX SERVOMOTOR Disconnect the connector. Remove the 3 screws and the air mix servomotor. Release the claw and remove the wire harness.
4. REMOVE AIR DUCT (Foot Duct) Remove the 2 screws and air duct.
5. REMOVE AIR DUCT (Vent Duct) Disconnect the mode damper control link. Remove the 2 screws and the air duct.

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

Scheme 192

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Scheme 198

1. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant.
2. DISCONNECT WATER HOSES FROM HEATER RADIATOR PIPES Using pliers, grip the claws of the clip and slide the clip along the hose Disconnect the water hoses HINT: At the time of installation, push the water hose on to the heater radiator pipe to the second ridge on the pipe.
3. REMOVE FRONT SEATS
4. REMOVE REAR CONSOLE BOX
5. REMOVE FRONT CONSOLE BOX COVER
6. REMOVE LOWER CENTER CLUSTER FINISH PANEL
7. REMOVE FRONT DOOR SCUFF PLATE
8. REMOVE COWL SIDE TRIMS
9. REMOVE REAR DOOR SCUFF PLATES
10. REMOVE CENTER PILLAR GARNISHES
11. SLIDE FLOOR CARPET BACKWARD
12. REMOVE COOLER BRACKET Remove the 4 bolts and the cooler bracket.
13. REMOVE REAR HEATER DUCT Remove the bolt, the screw and the rear heater duct.
14. REMOVE REAR HEATER UNIT Disconnect the connector. Remove the 3 bolts and the rear heater unit.

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Scheme 205

1. REMOVE AIR MIX SERVOMOTOR Remove the 3 screws and the air mix servomotor.
2. REMOVE HEATER RADIATOR Remove the 3 screws and 2 clamps Pull out the heater radiator. Remove the 2 screws, 2 clamps and the heater radiator pipes. Remove the 2 O-rings. HINT: At the time of reassembly, do not reuse the O-rings
3. REMOVE POWER TRANSISTOR Remove the 2 screws and the power transistor.
4. REMOVE BLOWER MOTOR Remove the 3 screws and the cover. Remove the 4 screws, the 3 holding springs and separate the heater cases. Remove the nut and the fan. Remove the screws and the blower motor.

Scheme 206

1. INSPECT HEATER RADIATOR If the fins are clogged, clean them with compressed air.
2. INSPECT BLOWER MOTOR OPERATION Connect battery positive (+) lead to terminal 1 and battery negative (-) lead to terminal 2, then check that the motor rotates smoothly. If operation is not as specified, replace the blower motor.
3. INSPECT AIR MIX SERVOMOTOR (See «DTC 47 REAR AIR MIX DAMPER CONTROL SERVOMOTOR CIRCUIT»(ref-215708-S00731768932006011800000) )
4. INSPECT AIR MIX DAMPER POSITION SENSOR (See «DTC 37, 47 REAR AIR MIX DAMPER POSITION SENSOR CIRCUIT»(ref-215708-S22000707432006011800000) )

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

Scheme 207

Scheme 208

1. REMOVE FRONT COOLING UNIT (See «REMOVAL»(ref-215765-S24117320832006081800000) )
2. REMOVE BLOWER UNIT Disconnect the connectors. Remove the bolt, 2 nuts and the blower unit.

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Scheme 211

1. REMOVE AIR INLET SERVOMOTOR Remove the 3 screws and the air inlet servomotor.
2. REMOVE BLOWER MOTOR CONTROL RELAY Disconnect the connector. Remove the screw and the blower motor control relay.
3. REMOVE BLOWER MOTOR Disconnect the connector. Remove the 3 screws and the blower motor.
4. REMOVE WIRE HARNESS Remove the screw and the wire harness.

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

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Scheme 213

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-215765-S32738938572006011900000) )
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 terminal 1 and 2. Standard resistance: 570 - 1,050 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 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.

Scheme 214

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Scheme 216

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-215765-S22076430312006081800000) )
7. DISCONNECT DISCHARGE AND SUCTION HOSES Remove the 2 bolts and disconnect the both suction hoses. NOTE: Cap the open fitting immediately to keep moisture or dirt out of the system.
8. REMOVE FRONT DRIVE SHAFT LH (See «REMOVAL»(ref-164315-S18302051192004073000000) )
9. REMOVE COMPRESSOR Disconnect the connector. Remove the 3 bolts and the compressor.

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Scheme 227

1. REMOVE PRESSURE PLATE Using SST and a socket wrench, remove the shaft bolt. Torque: 13.2 N.m (135 kgf.cm, 9 ft.lbf) SST 07112-76060 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, the snap ring should be installed so that beveled side facing 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, the snap ring should be installed so that its beveled side facing up. Remove the stator.

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

Scheme 228

Scheme 229

1. INSPECT FOR LEAKAGE OF REFRIGERANT Remove the glove compartment door. Remove the lower No. 2 finish panel (See «REMOVAL»(ref-215758-S06668151382006011900000) ). Remove the No. 1 cooler cover. Disconnect the connector clamp. Remove the 8 screws and No. 1 cooler cover. Using a gas leak detector, check for leaks of refrigerant. If there is a leakage of refrigerant, check the tightening torque at the joints or check the evaporator. Install the No. 1 cooler cover.
2. INSPECT EXPANSION VALVE Check amount of gas during refrigeration cycle. Set on manifold gauge set. Operate A/C system at "MAX. COOL" for approx. 5 minutes. Check expansion valve. Check the low pressure reading drops to 0 kPa (0 kgf/cm 2 , 0 psi). If the low pressure reading is not as specified, replace the expansion valve with the tubes.

Scheme 230

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Scheme 232

1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, evacuate air from refrigeration system and charge the system with the refrigerant and inspect for leaks of the refrigerant. Specified amount: 1,050 +/- 50 g (37.03 +/- 1.76 oz.)
2. DISCONNECT LIQUID AND SUCTION TUBES FROM FRONT COOLING UNIT (See «REMOVAL»(ref-215765-S24117320832006081800000) )
3. REMOVE INSTRUMENT PANEL (See «REMOVAL»(ref-215758-S06668151382006011900000) )
4. REMOVE ANTENNA RELAY Disconnect the connector. Remove the 2 screws and the antenna relay.
5. REMOVE EVAPORATOR Disconnect the connector. Disconnect the connector clamp. Remove the 8 screws and the No 1 cooler cover. Pull out the evaporator.

Scheme 233

Scheme 234

1. PULL OUT EVAPORATOR TEMPERATURE SENSOR
2. REMOVE EXPANSION VALVE Using a hexagon wrench (5.0 mm, 0.20 in.), remove the 2 bolts and separate the expansion valve and the evaporator. Torque: 3.4 N.m (35 kgf.cm, 30 in.lbf) NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system. HINT: At the time of reassembly, lubricate 4 new O-rings with compressor oil and install them to the valve if evaporator is replaced, add compressor oil to the evaporator. Add: 40 cc (1.4 fl.oz.) Compressor oil: ND-OIL8 or equivalent

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

Scheme 235

1. REMOVE BLOWER MOTOR Disconnect the connector. Remove the 3 screws and the blower motor.
2. INSPECT BLOWER MOTOR CIRCUIT (See «BLOWER MOTOR CIRCUIT»(ref-215708-S02724875752006011800000) )
3. INSTALL BLOWER MOTOR Install the blower motor with 3 screws. Connect the connector.

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Scheme 238

1. REMOVE BLOWER MOTOR CONTROL RELAY Disconnect the connectors. Remove the screw and the blower motor control relay.
2. INSPECT BLOWER MOTOR CONTROL RELAY Connect the connector to the blower motor control relay and inspect the wire harness side connector from the back side (Scheme 237) Test condition: Turn ignition switch to ON If circuit is not as specified, replace the relay

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Scheme 241

1. REMOVE REAR DOOR SCUFF PLATE RH
2. REMOVE REAR FLOOR MAT SUPPORT PLATE
3. REMOVE QUARTER TRIM PANEL RH
4. REMOVE POWER TRANSISTOR Disconnect the connector. Remove the 2 screws and the power transistor.
5. INSPECT POWER TRANSISTOR OPERATION Connect the positive (+) lead to terminal 1 through a 12 V - 3.4 W test bulb and negative (-) lead to terminal 2. Check the test bulb comes on when another positive (+) lead is connected to terminal 4 through a 12 V - 3.4 W test bulb. If operation is not as specified, replace the power transistor.
6. INSPECT POWER TRANSISTOR RESISTANCE Measure resistance between terminal 3 and 4. Standard resistance: 2.0 - 2.4 kohms If resistance is not as specified, replace the power transistor.
7. INSTALL POWER TRANSISTOR Install the power transistor with 2 screws. Connect the connector.
8. INSTALL QUARTER TRIM PANEL RH
9. INSTALL REAR FLOOR MAT SUPPORT PLATE
10. INSTALL REAR DOOR SCUFF PLATE RH

Scheme 242

1. REMOVE FRONT SEATS
2. REMOVE REAR CONSOLE BOX
3. REMOVE FRONT CONSOLE BOX COVER
4. REMOVE LOWER CENTER CLUSTER FINISH PANEL
5. REMOVE FRONT DOOR SCUFF PLATES
6. REMOVE COWL SIDE TRIMS
7. REMOVE REAR DOOR SCUFF PATES
8. REMOVE CENTER PILLAR GARNISHES
9. REMOVE POWER TRANSISTOR Slide the floor carpet backward. Disconnect the connector. Remove the 2 screws and power transistor.
10. INSPECT POWER TRANSISTOR Check the power transistor in the same way as for "POWER TRANSISTOR (For Rear Cooler)" on «INSPECTION»(ref-215765-S21764540232006081800000) .
11. INSTALL POWER TRANSISTOR
12. INSTALL CENTER PILLAR GARNISHES
13. INSTALL REAR DOOR SCUFF PATES
14. INSTALL COWL SIDE TRIMS
15. INSTALL FRONT DOOR SCUFF PLATES
16. INSTALL LOWER CENTER CLUSTER FINISH PANEL
17. INSTALL FRONT CONSOLE BOX COVER
18. INSTALL REAR CONSOLE BOX
19. INSTALL FRONT SEATS

Scheme 243

1. REMOVE AIR MIX SERVOMOTOR Disconnect the connector. Remove the 2 screws and the air mix servomotor.
2. INSPECT AIR MIX SERVOMOTOR OPERATION (See «DTC 41 FRONT AIR MIX DAMPER CONTROL SERVOMOTOR CIRCUIT»(ref-215708-S36195570822006011800000) )
3. INSPECT AIR MIX DAMPER POSITION SENSOR (See «DTC 31, 41 FRONT AIR MIX DAMPER POSITION SENSOR CIRCUIT»(ref-215708-S14761777612006011800000) )
4. INSTALL SERVOMOTOR Install the servomotor with the 3 screws. Connect the connector.

Scheme 244

Scheme 245

1. REMOVE LOWER NO. 1 PANEL (See «REMOVAL»(ref-215758-S06668151382006011900000) )
2. REMOVE AIR OUTLET SERVOMOTOR Disconnect the connector. Remove the 3 screws and the air outlet servomotor.
3. INSPECT AIR OUTLET SERVOMOTOR OPERATION Connect the positive (+) lead from the battery to terminal 6 and the negative (-) lead to terminal 7. Connect the negative (-) lead from the battery to each terminal and check that the shaft rotates at each position (Scheme 245) CONNECTED TERMINAL - POSITION Connected terminal Position 5 DEF. 4 FOOT/DEF. 3 FOOT 2 B/L 1 FACE If operation is not as specified, replace the servomotor.
4. INSTALL AIR OUTLET SERVOMOTOR Install the air outlet servomotor with the 3 screws. Connect the connector.

Scheme 246

1. REMOVE SOLAR SENSOR Using a screwdriver, pull out the solar sensor, then disconnect the connector. HINT: Tape up the screwdriver tip before use.
2. INSPECT SOLAR SENSOR CIRCUIT (See «DTC 21 SOLAR SENSOR CIRCUIT»(ref-215708-S29153517662006011800000) )
3. INSTALL SOLAR SENSOR Connect the connector. Insert the solar sensor to the instrument panel.

Scheme 247

1. REMOVE ROOM TEMPERATURE SENSOR Remove the lower No. 1 panel set screw. Release the lower No. 1 panel set claws. Disconnect the connector and the aspirator hose. Remove the screw and the room temperature sensor.
2. INSPECT ROOM TEMPERATURE SENSOR CIRCUIT (See «DTC 11 FRONT ROOM TEMPERATURE SENSOR CIRCUIT»(ref-215708-S13071177212006011800000) )
3. INSTALL ROOM TEMPERATURE SENSOR Install the room temperature sensor to the lower No. 1 panel with the screw. Connect the aspirator hose and the connector. Install the lower No. 1 panel with the screw.

Scheme 248

1. REMOVE ROOM TEMPERATURE SENSOR Using a screwdriver, pull out the room temperature sensor, then disconnect the connector. HINT: Tape the screwdriver tip before use.
2. INSPECT ROOM TEMPERATURE SENSOR (See «DTC 19 REAR ROOM TEMPERATURE SENSOR CIRCUIT»(ref-215708-S32851788462006011800000) )
3. INSTALL ROOM TEMPERATURE SENSOR Connect the connector. Insert the room temperature sensor to the roof headlining.

Scheme 249

1. REMOVE AMBIENT TEMPERATURE SENSOR Disconnect the connector. Remove the bolt and the ambient temperature sensor.
2. INSPECT AMBIENT TEMPERATURE SENSOR CIRCUIT (See «DTC 12 AMBIENT TEMPERATURE SENSOR CIRCUIT»(ref-215708-S37110421432006011800000) )
3. INSTALL AMBIENT TEMPERATURE SENSOR Install the ambient temperature sensor to the condenser upper bracket. Connect the connector.

Scheme 250

1. REMOVE FRONT SEATS
2. REMOVE REAR CONSOLE BOX
3. REMOVE FRONT CONSOLE BOX COVER
4. REMOVE LOWER CENTER CLUSTER FINISH PANEL
5. REMOVE FRONT DOOR SCUFF PLATES
6. REMOVE COWL SIDE TRIMS
7. REMOVE REAR DOOR SCUFF PATES
8. REMOVE CENTER PILLAR GARNISHES
9. REMOVE AIR INLET TEMPERATURE SENSOR Slide the floor carpet backward. Disconnect the connector. Remove the screw and the air inlet temperature sensor.
10. INSPECT AIR INLET TEMPERATURE SENSOR CIRCUIT (See «DTC 26 REAR INLET AIR TEMPERATURE SENSOR CIRCUIT»(ref-215708-S17179166522006011800000) )
11. INSTALL AIR INLET TEMPERATURE SENSOR Install the air inlet temperature sensor with the screw. Connect the connector. Install the floor carpet.
12. INSTALL CENTER PILLAR GARNISHES
13. INSTALL REAR DOOR SCUFF PLATES
14. INSTALL COWL SIDE TRIMS
15. INSTALL FRONT DOOR SCUFF PLATES
16. INSTALL REAR CONSOLE BOX
17. INSTALL FRONT SEATS

Scheme 251

1. REMOVE SMOG VENTILATION SENSOR Disconnect the connector. Remove the bolt and the smog ventilation sensor.
2. INSPECT SMOG VENTILATION SENSOR (See «DTC 18 EXHAUST GAS SENSOR CIRCUIT (HC, CO)»(ref-215708-S23687461862006011800000) )
3. INSTALL SMOG VENTILATION SENSOR Install the smog ventilation sensor with the bolt. Connect the connector.

Scheme 252

Scheme 253

1. SET VEHICLE IN THESE CONDITION Engine speed at 1,500 RPM Blower speed control switch at "HI" position Temperature control dial at "MAX. COOL" position Manifold gauge set setting.
2. INSPECT PRESSURE SWITCH OPERATION Disconnect the connector. Inspect pressure switch continuity (Magnetic Clutch Control) Connect the positive (+) lead from the ohmmeter to terminal 4 and the negative (-) lead to terminal 1. Check continuity between terminals when refrigerant pressure changes, as shown in the illustration. If continuity is not as specified, replace the pressure switch.

Scheme 254

1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, refer to the following items. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for any leakage of refrigerant. Specified amount: 1,050 +/- 50 g (37.03 +/- 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, be careful not to deform the tube, and remove the pressure switch. At the time of installation, lubricate a new O-ring with compressor oil and install the pressure switch.

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

Scheme 255

Scheme 256

1. REMOVE HEATER MAIN RELAY Remove the heater main relay.
2. INSPECT HEATER MAIN RELAY CONTINUITY HEATER MAIN RELAY CONTINUITY TABLE Condition Tester connection Specified condition Constant 1 - 2; 3 - 4 Continuity Apply B+ between terminals 1 and 2. 3 - 5 Continuity If continuity is not as specified, replace the relay.
3. INSTALL HEATER MAIN RELAY

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

HINT

w/ LEXUS Navigation System

When removing/installing or replacing EMV, or when disconnecting/connecting the battery terminal, turn the IG ON and OFF twice for initial display setting.

Scheme 257

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Scheme 262

1. REMOVE REAR HEATER CONTROL ASSEMBLY Using a screwdriver, release the 4 claws and pull out the rear heater control assembly, then disconnect the connector.
2. INSPECT ILLUMINATION OPERATION Connect the positive (+) lead to terminal 2 and negative (-) lead to terminal 21 then check that the indicators come on. If operation is not as specified, replace the rear A/C control assembly.
3. INSPECT INDICATOR OPERATION Connect the positive (+) lead all the other terminals to terminal 1 and negative (-) lead to, then check that the indicator comes on, as shown in «INDICATOR SWITCH - TESTER CONNECTION»(ref-215765-S03958479422006040800000) . INDICATOR SWITCH - TESTER CONNECTION Switch Tester connection Auto 3 LO 4 ME 5 HI 6 FACE 7 Bi-Level 8 FOOT 9 If operation is not as specified, replace the rear A/C control assembly. Connect the positive (+) lead from the battery to terminal 2, then check whether the indicators dim. If operation is not as specified, replace the rear A/C control assembly.
4. INSPECT SWITCH CONTINUITY Check the continuity between terminals while switch is pressed, as shown in «SWITCH CONTINUITY»(ref-215765-S16523322202006040800000) . SWITCH CONTINUITY Switch Tester connection Specified condition Auto 13 - 22 Continuity OFF 14 - 22 Continuity LO 15 - 22 Continuity ME 16 - 22 Continuity HI 17 - 22 Continuity FACE 18 - 22 Continuity Bi-Level 19 - 22 Continuity FOOT 20 - 22 Continuity If continuity is not as specified, replace the rear A/C control assembly.
5. INSPECT VARIABLE RESISTOR OPERATION Measure resistance between terminal 10 and 12. Standard resistance: 3.0 kohms Gradually move the temperature control lever from "COOL" side to "WARM" side, then check that the resistance between terminal 11 and 12 increase to 3.0 kohms. If operation is not as specified, replace the rear A/C control assembly.
6. INSTALL HEATER CONTROL ASSEMBLY

Scheme 263

1. REMOVE REAR DOOR SCUFF PLATE RH
2. REMOVE REAR FLOOR MAT SUPPORT PLATE
3. REMOVE QUARTER TRIM PANEL RH
4. REMOVE A/C AMPLIFIER Disconnect the connectors. Remove the 2 screws and the A/C amplifier.
5. INSPECT REAR A/C AMPLIFIER CIRCUIT (See «TERMINALS OF ECU»(ref-215708-S00533108252006011800000) )

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1. REMOVE GLOVE COMPARTMENT DOOR
2. REMOVE LOWER NO. 2 FINISH PANEL
3. REMOVE AIR REFINER FILTER Release the 2 claws and remove the filter cover. Pull out the air refiner filter (Upper side). Pull out the filter upward, pull out the air refiner filter (Lower side).
4. INSTALL AIR REFINER FILTER Install the air refiner filter (Lower side). Install the air refiner filter (Upper side). Install the filter cover.
5. INSTALL LOWER NO. 2 FINISH PANEL
6. INSTALL GLOVE COMPARTMENT DOOR