Air Conditioning System: Overhaul Lexus RX II

OVERHAUL

HINT

See ( COMPONENTS & COMPONENTS ).

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1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See «REPLACEMENT»(ref-215980-S01494776952006011900000) ) SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
2. REMOVE FR WIPER ARM RH (See «REPLACEMENT»(ref-209594-S11562562152005121000000) )
3. REMOVE FR WIPER ARM LH (See «REPLACEMENT»(ref-209594-S11562562152005121000000) )
4. REMOVE FRONT FENDER TO COWL SIDE SEAL RH (See «REPLACEMENT»(ref-209594-S11562562152005121000000) )
5. REMOVE FRONT FENDER TO COWL SIDE SEAL LH (See «REPLACEMENT»(ref-209594-S11562562152005121000000) )
6. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See «REPLACEMENT»(ref-209594-S11562562152005121000000) )
7. REMOVE WINDSHIELD WIPER LINK ASSY (See «REPLACEMENT»(ref-209594-S11562562152005121000000) )
8. REMOVE FRONT SHOCK ABSORBER CAP RH (W/ AIR SUSPENSION) (See «SHOCK ABSORBER (PNEUMATIC CYLINDER)»(ref-165164-S03442303962004082000000) )
9. REMOVE FRONT SHOCK ABSORBER CAP LH (W/ AIR SUSPENSION) (See «SHOCK ABSORBER (PNEUMATIC CYLINDER)»(ref-165164-S03442303962004082000000) )
10. REMOVE COWL TOP PANEL SUB-ASSY OUTER Remove the clamp and disconnect the rubber grommet. Remove the 4 bolts, 6 nuts and cowl top panel sub-assy outer.
11. DISCONNECT LIQUID TUBE SUB-ASSY A Install SST(s) on piping clamp. SST 09870-00025 HINT: Make sure the direction of the piping clamp claw and SST(s) by seeing the illustration shown on the caution label. Push down SST(s) and release the clamp lock. NOTE: Be careful not to deform the tube when pushing SST(s). Pull SST(s) slightly and push the release lever, and then remove the piping clamp with SST(s). Disconnect the liquid tube sub-assy A. NOTE: Do not use tools like screwdriver to remove the tube. Cap the open fittings immediately to keep moisture or dirt out of the system. Remove the 2 O-rings from the liquid tube sub-assy A.
12. DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO.1 SST 09870-00015 HINT: Disconnection of the cooler refrigerant suction hose No.1 is same as the liquid tube sub-assy.
13. DISCONNECT HEATER OUTLET WATER HOSE Using pliers, grip the claws of the clip and slide the clip, and then disconnect the heater outlet water hose. NOTE: Do not apply any excessive force to the heater outlet water hose. Prepare a drain pan or cloth for when the cooling water leaks.
14. DISCONNECT HEATER INLET WATER HOSE HINT: Disconnection of the heater water inlet hose is same as the heater outlet water hose.
15. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY W/PASSENGER AIR BAG ASSY (See «REPLACEMENT»(ref-209595-S07742720212005121000000) ) HINT: Refer to the instructions for removal of the instrument panel safety pad sub-assy w/ passenger air bag assy.
16. REMOVE ECM (See «REPLACEMENT»(ref-239231-S14816638622006072700000) )
17. REMOVE AIR CONDITIONER AMPLIFIER ASSY (See «AIR CONDITIONER AMPLIFIER ASSY»(ref-215980-S05678401652006011900000) )
18. REMOVE AIR DUCT REAR NO.2 Take up the floor carpet. HINT: Take up the floor carpet so that the air duct rear No.2 can be removed. Release the claw fitting and remove the air duct rear No.2.
19. REMOVE AIR DUCT REAR NO.1 Take up the floor carpet. HINT: Take up the floor carpet so that the air duct rear No.1 can be removed. Release the claw fitting and remove the air duct rear No. 1.
20. REMOVE AIR DUCT NO.1 Remove the bolt. Release the 3 claw fittings and remove the air duct No.1.
21. SEPARATE TRANSMISSION CONTROL CABLE ASSY (See «OVERHAUL»(ref-209590-S27089889222005121000000) )
22. REMOVE SHIFT LEVER ASSY (See «OVERHAUL»(ref-209590-S27089889222005121000000) )
23. REMOVE INSTRUMENT PANEL BRACKET NO.4 Remove the 4 nuts and instrument panel bracket No.4.
24. REMOVE INSTRUMENT PANEL BRACE SUB-ASSY NO.1 Remove the clamp and disconnect the connector. Remove the 3 bolts and 2 nuts and instrument panel brace sub-assy No.1.
25. REMOVE INSTRUMENT PANEL BRACE SUB-ASSY NO.2 Remove the clamp and disconnect the connector. Remove the 3 bolts and 2 nuts and instrument panel brace sub-assy No.2.
26. SEPARATE STEERING INTERMEDIATE SHAFT SUB-ASSY MANUAL TILT: (See «OVERHAUL»(ref-209591-S37267927122005121000000) ) POWER TILT & TELESCOPIC: (See «OVERHAUL»(ref-209591-S40521614872005121000000) )
27. REMOVE STEERING COLUMN ASSY MANUAL TILT: (See «OVERHAUL»(ref-209591-S37267927122005121000000) ) POWER TILT & TELESCOPIC: (See «OVERHAUL»(ref-209591-S40521614872005121000000) )
28. REMOVE AIR DUCT SUB-ASSY NO.1 Remove the 3 nuts and air duct sub-assy No.1.
29. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSY Remove the 4 bolts and 4 nuts. Remove the clamp. Disconnect the connectors. Remove the 9 bolts and the 2 nuts and then remove the instrument panel reinforcement while holding the air conditioner unit assy HINT: Make sure to keep the air conditioner unit assy unmoved as the installation parts of the bracket in the air conditioner unit assy could be damaged.
30. REMOVE AIR CONDITIONER UNIT ASSY Remove the 2 nuts and air conditioner unit assy. HINT: Make sure to keep the air conditioner unit assy unmoved as the installation parts of the bracket in the air conditioner unit assy could be damaged.
31. REMOVE AIR DUCT NO.2 Remove the screw. Release the 2 claw fittings and remove the air duct No.2.
32. REMOVE WIRING AIR INDICATOR HARNESS SUB-ASSY NO.2 Remove the 3 screws. Remove the clamp and disconnect the 2 connectors.
33. REMOVE BLOWER ASSY Remove the screw. Release the claw fitting and remove the blower assy.
34. REMOVE HEATER TO REGISTER DUCT CENTER Release the 4 claw fittings and remove the heater to register duct center.
35. REMOVE MODE DAMPER SERVO SUB-ASSY Remove the 3 screws and mode damper servo sub-assy.
36. REMOVE AIRMIX DAMPER SERVO SUB-ASSY LH side: Remove the 3 screws and air mix damper servo sub-assy. RH side: Remove the 3 screws and air mix damper servo sub-assy.
37. REMOVE COOLER THERMISTOR NO.1 Release the clamp and connector. Release the 2 claws fittings and remove cooler thermistor No.1.
38. REMOVE HEATER RADIATOR UNIT SUB-ASSY Remove the 2 screws and piping cover. Remove the screw and bracket. Remove the heater radiator unit sub-assy. NOTE: Prepare a drain pan or cloth for when the cooling water leaks.
39. REMOVE AIR CONDITIONING TUBE ASSY Remove the packing. Using a hexagon wrench 4.0 mm (0.15 in.), remove the 2 hexagon bolts and air conditioning tube assy. Remove the 2 O-rings from the air conditioning tube assy.
40. REMOVE COOLER EXPANSION VALVE Remove the cooler expansion valve from the cooler evaporator sub-assy No.1.
41. REMOVE COOLER EVAPORATOR SUB-ASSY NO.1 Remove the 3 screws and air duct sub-assy. Release the 4 claw fittings and remove the air duct sub-assy. Remove the 11 screws and separate the heater case. Remove the cooler evaporator sub-assy No.1. Remove the 2 O-rings from the cooler evaporator sub-assy No.1.
42. INSTALL COOLER EVAPORATOR SUB-ASSY NO.1 Sufficiently apply compressor oil to the 2 new O-rings and fitting surface of the cooler expansion valve. Compressor oil: ND-OIL8 or equivalent Install the 2 O-rings on the cooler evaporator sub-assy No.1. Install the cooler evaporator sub-assy No.1 to the heater case. Install the heater case with the 11 screws. Install the air duct sub-assy with the 4 claws. Install the air duct sub-assy with the 3 screws.
43. INSTALL COOLER EXPANSION VALVE Install the cooler expansion valve to the cooler evaporator sub-assy No. 1.
44. INSTALL AIR CONDITIONING TUBE ASSY Sufficiently apply compressor oil to the 2 new O-rings and fitting surface of the air conditioning tube assy. Compressor oil: ND-OIL8 or equivalent Install the 2 O-rings on the air conditioning tube assy. Using a hexagon wrench 4.0 mm (0.15 in.), install the air conditioning tube assy with the 2 hexagon bolts. Torque: 3.5 N.m (35 kgf.cm, 30 in..lbf) Install the packing. NOTE: Be sure to install the packing securely so that there is no clearance. Wrap the packing (Scheme 379)to keep out moisture.
45. INSTALL AIR DUCT NO.2 Install the air duct No.2 with the screw. Torque: 2.5 N.m (25 kgf.cm, 22 in..lbf)
46. TEMPORARILY TIGHTEN AIR CONDITIONER UNIT ASSY Temporarily tighten the air conditioner unit assy with the 2 nuts. HINT: Make sure to keep the air conditioner unit assy unmoved as the installation parts of the bracket in the air conditioner unit assy could be damaged.
47. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSY Install the instrument panel reinforcement with the 8 bolts. Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) Temporarily tighten the air conditioner unit assy with the 2 nuts and bolt. Install the 4 bolts and 4 nuts. Install the clamps. Connect the connectors.
48. INSTALL INSTRUMENT PANEL BRACE SUB-ASSY NO.2 Install the instrument panel brace sub-assy No.2 with the 3 bolts and 2 nuts. Install the clamps and connect the connectors.
49. INSTALL INSTRUMENT PANEL BRACE SUB-ASSY NO.1 Install the instrument panel brace sub-assy No.1 with the 3 bolts and 2 nuts. Install the clamps and connect the connectors.
50. INSTALL AIR DUCT SUB-ASSY NO.1 Install the air duct sub-assy No.1 with the 3 nuts. Torque: 9.8 N.m (100 kgf.cm, 87 in..lbf) NOTE: Tighten the bolts in numerical order (Scheme 387)to install the air duct sub-assy No.1.
51. FULLY TIGHTEN AIR CONDITIONER UNIT ASSY Fully tighten the air conditioner unit assy with the 3 bolts and 4 nuts. Torque: 9.8 N.m (100 kgf.cm, 87 in..lbf) NOTE: Tighten the bolts in numerical order (Scheme 388)to install the air conditioner unit assy. Install the air conditioner unit assy so that there is no clearance between the duct and blower assy.
52. INSTALL AIR DUCT NO.1 Install the air duct No.1 with the bolt. Torque: 9.8 N.m (100 kgf.cm, 87 in..lbf)
53. INSTALL STEERING COLUMN ASSY MANUAL TILT: (See «OVERHAUL»(ref-209591-S37267927122005121000000) ) POWER TILT & TELESCOPIC: (See «OVERHAUL»(ref-209591-S40521614872005121000000) )
54. CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSY MANUAL TILT: (See «OVERHAUL»(ref-209591-S37267927122005121000000) ) POWER TILT & TELESCOPIC: (See «OVERHAUL»(ref-209591-S40521614872005121000000) )
55. INSTALL ECM (See «REPLACEMENT»(ref-239231-S14816638622006072700000) )
56. INSTALL SHIFT LEVER ASSY (See «OVERHAUL»(ref-209590-S27089889222005121000000) )
57. CONNECT TRANSMISSION CONTROL CABLE ASSY (See «OVERHAUL»(ref-209590-S27089889222005121000000) )
58. INSPECT SHIFT LEVER POSITION (See «OVERHAUL»(ref-209590-S27089889222005121000000) )
59. ADJUST SHIFT LEVER POSITION (See «ADJUSTMENT»(ref-209590-S40614849362005121000000) )
60. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY W/PASSENGER AIR BAG ASSY (See «REPLACEMENT»(ref-209595-S07742720212005121000000) )
61. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 Remove the attached vinyl tape from the hose. Coat a new O-ring with compressor oil and install it to the hose. Compressor oil: ND-OIL 8 or equivalent Install the cooler refrigerant suction hose No.1 and piping clamp. HINT: Be sure to connect the hose securely. After connection, check the fitting for claw of the piping clamp.
62. INSTALL LIQUID TUBE SUB-ASSY A Remove the attached vinyl tape from the hose. Coat a new O-ring with compressor oil and install it to the pipe. Compressor oil: ND-OIL 8 or equivalent Install the liquid tube sub-assy A and piping clamp. HINT: Be sure to connect the hose securely. After connection, check the fitting for claw of the piping clamp.
63. INSTALL COWL TOP PANEL SUB-ASSY OUTER Install the cowl top panel sub-assy outer with the 4 bolts and 6 nuts. Torque: 80 N.m (816 kgf.cm, 59 ft.lbf)
64. INSTALL FRONT SHOCK ABSORBER CAP LH (W/ AIR SUSPENSION) (See «SHOCK ABSORBER (PNEUMATIC CYLINDER)»(ref-165164-S03442303962004082000000) )
65. INSTALL FRONT SHOCK ABSORBER CAP RH (W/ AIR SUSPENSION) (See «SHOCK ABSORBER (PNEUMATIC CYLINDER)»(ref-165164-S03442303962004082000000) )
66. ADD ENGINE COOLANT (See «REPLACEMENT»(ref-209567-S13122537132005121000000) )
67. CHARGE REFRIGERANT (See «REPLACEMENT»(ref-215980-S01494776952006011900000) ) SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060,07117-88070, 07117-88080) Specified amount: 600 +/- 50 g (21.15 +/- 1.76 oz.)
68. WARM UP ENGINE (See «REPLACEMENT»(ref-215980-S01494776952006011900000) )
69. CHECK FOR ENGINE COOLANT LEAKS (See «ON-VEHICLE INSPECTION»(ref-209566-S27713500342005121000000) )
70. INSPECT LEAKAGE OF REFRIGERANT (See «REPLACEMENT»(ref-215980-S01494776952006011900000) )

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HINT

1. «COMPONENTS»(ref-215980-S23733463932006011900000) : See , «BLOWER ASSY»(ref-215980-S32262687282006011900000)
2. When removing the cooling unit motor sub assy with fan, follow procedures 1 through 7 and 10.

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1. REMOVE FRONT DOOR SCUFF PLATE RH (See «REPLACEMENT»(ref-209595-S07742720212005121000000) )
2. REMOVE COWL SIDE TRIM SUB-ASSY RH (See «REPLACEMENT»(ref-209595-S07742720212005121000000) )
3. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.2 (See «REPLACEMENT»(ref-209595-S07742720212005121000000) )
4. REMOVE GLOVE COMPARTMENT DOOR ASSY (See «REPLACEMENT»(ref-209595-S07742720212005121000000) )
5. REMOVE ECM (See «REPLACEMENT»(ref-239231-S14816638622006072700000) )
6. REMOVE AIR DUCT NO.2 Remove the screw. Release the 2 claw fittings and remove the air duct No.2.
7. DISCONNECT WIRING AIR INDICATOR HARNESS SUB-ASSY NO.2 Remove the clamp and disconnect the connectors.
8. REMOVE BLOWER ASSY Remove the clamp and disconnect the connectors. Remove the 4 screws and the nut, and then the bracket. Remove the bolt and 2 screws. Release the claw fitting and remove the blower assy.
9. REMOVE RECIRCULATION DAMPER SERVO SUB-ASSY Remove the 3 screws and recirculation damper servo sub-assy.
10. REMOVE COOLING UNIT MOTOR SUB-ASSY W/FAN Remove the 3 screws and cooling unit motor sub-assy w/ fan.
11. REMOVE BLOWER MOTOR CONTROL Remove the 2 screws and blower motor control.
12. REMOVE CLEAN AIR FILTER Release the 2 claw fittings and remove the air filter sub-assy. Remove the air refiner element from the air filter cover plate.
13. INSTALL BLOWER ASSY Install the blower assy with the claw fitting. Install the bolt and 2 screws. Torque: 9.8 N.m (100 kgf.cm, 87in..lbf) (Bolt) Install the bracket with the 4 screws and nut. Torque: 9.8 N.m (100 kgf.cm, 87in..lbf) (Nut) Install the clamp and connect the connectors.
14. INSTALL AIR DUCT NO.2 Install the air duct No.2 with the screw. Torque: 2.5 N.m (25 kgf.cm, 22 in..lbf)
15. INSTALL ECM (See «REPLACEMENT»(ref-239231-S14816638622006072700000) )

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HINT

COMPONENTS : See

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1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See «REPLACEMENT»(ref-215980-S01494776952006011900000) ) SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
2. DISCONNECT COOLER REFRIGERANT DISCHARGE PIPE A Remove the bolt and disconnect the cooler refrigerant discharge pipe A from the cooler condenser assy. Remove the O-ring from the cooler refrigerant discharge pipe A. NOTE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
3. DISCONNECT LIQUID TUBE SUB-ASSY A Remove the bolt and disconnect the liquid tube sub-assy A from the cooler condenser assy. Remove the O-ring from the liquid tube sub-assy A. NOTE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
4. REMOVE AIR CLEANER INLET NO.2 Release the vacuum hose. Remove the 2 bolts. Release the 2 clamps and remove the air cleaner inlet No.2.
5. REMOVE AIR CLEANER INLET NO.1 Remove the bolt and air cleaner inlet No.1.
6. DISCONNECT RADIATOR SUPPORT SUB-ASSY UPPER Remove the bolt and raise the bracket (Scheme 413) Remove the cap. Disconnect the connector. Remove the 5 bolts, nut and radiator support sub-assy.
7. REMOVE RADIATOR SUPPORT SUB-ASSY RH Release the 4 clamps and disconnect the connector. Remove the 6 bolts, 2 screws and 2 radiator support sub-assy RH.
8. REMOVE COOLER CONDENSER ASSY Remove the 2 screws and cooler condenser assy.
9. REMOVE COOLER DRYER Using hexagon wrench 14 mm (0.55 in.), remove the cap and filter from the modulator. Remove the O-ring from the cap. Using needle nose pliers, remove the cooler dryer.
10. INSTALL COOLER DRYER Using needle nose pliers, install the cooler dryer. Install new O-ring to the cap. Sufficiently apply compressor oil to the fitting surfaces of the O-ring and the cap. Compressor oil: ND-OIL 8 or equivalent Using hexagon wrench 14 mm (0.55 in.), install the cap to the cooler condenser assy. Torque: 2.9 N.m (30 kgf.cm, 25 in..lbf)
11. INSTALL COOLER CONDENSER ASSY Install the cooler condenser assy with the 2 screws. Torque: 3.9 N.m (40 kgf.cm, 35 in..lbf)
12. INSTALL RADIATOR SUPPORT SUB-ASSY RH Install the 2 radiator support sub-assy RH with the 6 bolts and 2 screws. Torque: 5.0 N.m (51 kgf.cm, 44 in..lbf) (A) 7.0 N.m (71 kgf.cm, 62 in..lbf) (B) 3.9 N.m (40 kgf.cm, 35 in..lbf) (C)
13. INSTALL RADIATOR SUPPORT SUB-ASSY UPPER Install the radiator support sub-assy upper with the 5 bolts and nut. Connect the connectors. Install the cap.
14. INSTALL LIQUID TUBE SUB-ASSY A Remove the attached vinyl tape from the tube and connecting part of the cooler condenser assy. Sufficiently apply compressor oil to the new O-ring and fitting surface of the pipe joint. Compressor oil: ND-OIL 8 or equivalent Install the O-ring on the liquid tube sub-assy A. Connect the air conditioning tube assy to the cooler condenser assy with the bolt. Torque: 5.4 N.m (55 kgf.cm, 47 in..lbf)
15. INSTALL COOLER REFRIGERANT DISCHARGE PIPE A Remove the attached vinyl tape from the tube and connecting part of the cooler condenser assy. Sufficiently apply compressor oil to the new O-ring and fitting surface of the pipe joint. Compressor oil: ND-OIL 8 or equivalent Install the O-ring to the discharge hose sub-assy. Connect the cooler refrigerant discharge pipe A on the cooler condenser assy with the bolt. Torque: 5.4 N.m (55 kgf.cm, 47 in..lbf)
16. CHARGE REFRIGERANT (See «REPLACEMENT»(ref-215980-S01494776952006011900000) ) SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060,07117-88070, 07117-88080) Specified amount: 600 +/- 50 g (21.15 +/- 1.76 oz.)
17. WARM UP ENGINE (See «REPLACEMENT»(ref-215980-S01494776952006011900000) )
18. INSPECT LEAKAGE OF REFRIGERANT (See «REPLACEMENT»(ref-215980-S01494776952006011900000) )

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1. REMOVE FRONT DOOR SCUFF PLATE RH (See «REPLACEMENT»(ref-209595-S07742720212005121000000) )
2. REMOVE COWL SIDE TRIM SUB-ASSY RH (See «REPLACEMENT»(ref-209595-S07742720212005121000000) )
3. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.2 (See «REPLACEMENT»(ref-209595-S07742720212005121000000) )
4. REMOVE GLOVE COMPARTMENT DOOR ASSY (See «REPLACEMENT»(ref-209595-S07742720212005121000000) )
5. REMOVE ECM Disconnect the connectors. Remove the 2 nuts and ECM.
6. REMOVE AIR CONDITIONER AMPLIFIER ASSY Disconnect the connectors. Remove the 2 nuts and air conditioner amplifier assy.
7. REMOVE SUSPENSION CONTROL ECU (W/ AIR SUSPENSION) (See «REPLACEMENT»(ref-209574-S23902783152005121000000) )
8. INSTALL SUSPENSION CONTROL ECU (W/ AIR SUSPENSION) (See «REPLACEMENT»(ref-209574-S23902783152005121000000) )
9. INSTALL ECM Install the ECM with the 2 nuts. Torque: 5.5 N.m (56 kgf.cm, 49 in..lbf)