LEMON Manuals: Even more car manuals for everyone
Home >> Lexus >> 2004 >> RX 330 AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 412 (Heater & Air Conditioner) >> Air Conditioning Radiator ASSY >> Overhaul

Air Conditioning Radiator ASSY: Overhaul

WARNING: This page is about a different car, the 2005 Toyota Sienna. However, it is still accessible from the selected car via links, so may be relevant.

HINT:

See COMPONENTS 

  1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See  REPLACEMENT  ) 

    SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)

  2. REMOVE FRONT WIPER ARM HEAD CAP (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  3. REMOVE FR WIPER ARM RH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  4. REMOVE FR WIPER ARM LH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  5. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  6. REMOVE WINDSHIELD WIPER MOTOR & LINK ASSY (See WINDSHIELD WIPER MOTOR ASSY  WINDSHIELD WIPER MOTOR ASSY  ) 
  7. REMOVE COWL TOP PANEL SUB-ASSY OUTER FRONT 
    1. Remove the 7 bolts and disconnect the cowl top panel sub-assy.
  8. DISCONNECT COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) 
    1. Install SST on the piping clamp.

      SST 09870-00025

      HINT:

      Make sure the direction of the piping clamp claw and SST by checking Fig 1on the caution label.

      Fig 1: Removing Bolts
      G02609898Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Push down SST and release the clamp lock.
      NOTE: Be careful not to deform the tube when pushing SST.
    3. Pull SST slightly and push the release lever, and then remove the piping clamp with SST.
      Fig 2: Releasing Clamp Lock
      G02609899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the cooler refrigerant liquid pipe (to cooler unit).
    NOTE:
    • Do not use tools like a screwdriver to remove the tube.
    • Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matters from entering.
    Fig 3: Disconnecting Cooler Refrigerant Liquid Pipe (To Cooler Unit)
    G02609900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. DISCONNECT SUCTION HOSE SUB-ASSY 

    SST 09870-00015

    HINT:

    Disconnection of the pipe cooler refrigerant suction hose sub-assy is the same way as the cooler refrigerant liquid pipe E (to cooler unit).

  10. REMOVE AIR CLEANER CAP SUB-ASSY (See  REPLACEMENT  ) 
  11. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) 
    1. Using pliers, grip the claws of the clip and slide the clip to disconnect the heater water outlet hose A (from heater unit).
    Fig 4: Disconnecting Heater Water Outlet Hose
    G02609901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. DISCONNECT HEATER WATER INLET HOSE A 

    HINT:

    Disconnection of the heater water inlet hose A is the same way as the heater water outlet hose A (from heater unit).

  13. REMOVE INSTRUMENT PANEL SUB-ASSY W/PASSENGER AIRBAG ASSY (See  REPLACEMENT  ) 

    HINT:

    Refer to the instructions for removal of the instrument panel sub-assy w/ passenger airbag assy.

  14. REMOVE HEATER TO FOOT DUCT NO. 3 
    1. Remove the clip and the heater to foot duct No. 3.
    Fig 5: Removing Clip & Heater To Foot Duct
    G02609902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE HEATER TO FOOT DUCT NO. 1 
    1. Remove the clip and the heater to foot duct No. 1.
    Fig 6: Removing Clip & Heater To Foot Duct No. 1
    G02609903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. DISCONNECT TRANSMISSION CONTROL CABLE ASSY (See  OVERHAUL  ) 
  17. REMOVE SHIFT LOCK CONTROL UNIT ASSY (See  OVERHAUL  ) 
  18. REMOVE INSTRUMENT PANEL BRACKET NO. 5 
    1. Release the 2 clamps and disconnect the connector.
      Fig 7: Disconnecting Connector & Releasing Clamps
      G02609904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 nuts and the instrument panel bracket No. 5.
    Fig 8: Removing Nuts
    G02609905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE INSTRUMENT PANEL BRACE SUB-ASSY NO. 1 
    1. Release the 4 clamps and remove the bolt and disconnect the connector.
      Fig 9: Releasing Clamps
      G02609906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts, the 2 nuts and the instrument panel brace sub-assy No. 1.
    Fig 10: Removing Bolts
    G02609907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE INSTRUMENT PANEL BRACE SUB-ASSY NO. 2 
    1. Release the 2 clamps and disconnect the connector.
      Fig 11: Disconnecting Connector & Releasing Clamps
      G02609908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts, the 2 nuts and the instrument panel brace sub-assy No. 2.
    Fig 12: Removing Bolts & Nuts
    G02609909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE STEERING COLUMN ASSY (See  OVERHAUL  ) 
  22. REMOVE ECM (See  REPLACEMENT  ) 
  23. REMOVE STEREO COMPONENT AMPLIFIER ASSY (W/ STEREO COMPONENT AMPLIFIER) (See  REPLACEMENT  ) 
  24. REMOVE FRONT FENDER GARNISH RH (See  REPLACEMENT  ) 
  25. REMOVE INSTRUMENT PANEL REINFORCEMENT 
    1. Remove the 6 nuts.
    2. Release the 13 clamps.
    3. Disconnect the connectors.
      Fig 13: Removing Nuts
      G02609910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 11 bolts, 2 nuts and the instrument panel reinforcement.
    Fig 14: Removing Bolts & Nuts
    G02609911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE DEFROSTER NOZZLE ASSY LOWER 
    1. Release the 4 claw fittings and remove the defroster nozzle assy lower.
    Fig 15: Releasing Claw Fittings
    G02609912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE AIR CONDITIONING UNIT ASSY 
    1. Release the 2 claw fittings and remove the nut and the air conditioning unit assy.
    Fig 16: Removing Nut & Air Conditioning Unit Assy & Releasing Claw Fittings
    G02609913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE BLOWER ASSY 
    1. Remove the 2 screws and the blower assy.
    Fig 17: Removing Screws & Blower Assy
    G02609914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE MODE DAMPER SERVO SUB-ASSY 
    1. Remove the 3 screws and the mode damper servo sub-assy.
    Fig 18: Removing Screws & Mode Damper Servo Sub-Assy
    G02609915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE AIRMIX DAMPER SERVO SUB-ASSY 
    1. Remove the 3 screws and the airmix damper servo sub-assy.
    Fig 19: Removing Screws & Airmix Damper Servo Sub-Assy
    G02609916Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE AIRMIX NO. 2 DAMPER SERVO SUB-ASSY (AUTO AIR CONDITIONING) 
    1. Remove the 3 screws and the airmix No. 2 damper servo sub-assy.
    Fig 20: Removing Screws & Airmix No. 2 Damper Servo Sub-Assy
    G02609917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE HEATER CLAMP NO. 1 
    1. Release the 4 claw fittings and remove the heater clamp No. 1.
    Fig 21: Removing Heater Clamp No. 1 & Releasing Claw
    G02609918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE AIR CONDITIONING RADIATOR BRACKET NO. 3 
    1. Remove the screw and the air conditioning radiator bracket No. 3.
    Fig 22: Removing Screw & Air Conditioning Radiator Bracket No. 3
    G02609919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE HEATER RADIATOR UNIT SUB-ASSY 
    1. Remove the heater radiator unit sub-assy from the air conditioning radiator assy.
    Fig 23: Removing Heater Radiator Unit Sub-Assy
    G02609920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE COOLER THERMISTOR NO. 1 
  36. REMOVE COOLING UNIT PACKING NO. 3 
    1. Remove the cooling unit packing No. 3
    Fig 24: Removing Cooling Unit Packing No. 3
    G02609921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE AIR CONDITIONING TUBE ASSY 
    1. Using a hexagon wrench 4.0 mm (0.15 in.), remove the 2 hexagon bolts and the air conditioning tube assy.
    2. Remove the 2 O-rings from the air conditioning tube assy.
    Fig 25: Removing O-Rings From Air Conditioning Tube Assy
    G02609922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE COOLER EXPANSION VALVE 
    1. Remove the cooler expansion valve from the cooler evaporator sub-assy No. 1.
      Fig 26: Removing Cooler Expansion Valve From Cooler Evaporator Sub-Assy No. 1
      G02609923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 O-rings from the cooler evaporator Sub-assy No. 1.
    Fig 27: Removing O-Rings From Cooler Evaporator Sub-Assy No. 1
    G02609924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE AIR CONDITIONING RADIATOR BRACKET NO. 2 
    1. Remove the 2 screws and the air conditioning radiator bracket No. 2.
    Fig 28: Removing Screws & Air Conditioning Radiator Bracket No. 2
    G02609925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE AIR CONDITIONING RADIATOR BRACKET NO. 1 
    1. Remove the 3 screws and the air conditioning radiator bracket No. 1.
    Fig 29: Removing Screws & Air Conditioning Radiator Bracket No. 1
    G02609926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE AIR CONDITIONING RADIATOR BRACKET NO. 4 
    1. Remove the air conditioning radiator bracket No. 4.
    Fig 30: Removing Air Conditioning Radiator Bracket No. 4
    G02609927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE AIR DUCT NO. 1 
    1. Release the 4 claw fittings and remove the air duct No. 1.
    Fig 31: Removing Air Duct & Releasing Claw
    G02609928Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL COOLER EXPANSION VALVE 
    1. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the cooler evaporator sub-assy No. 1.

      Compressor oil: ND-OIL 8 or equivalent 

      Fig 32: Installing Cooler Expansion Valve
      G02609929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the cooler expansion valve to the cooler evaporator sub-assy No. 1.
    Fig 33: Installing Cooler Expansion Valve To Cooler Evaporator Sub-Assy
    G02609930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL AIR CONDITIONING TUBE ASSY 
    1. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the air conditioning tube assy.

      Compressor oil: ND-OIL 8 or equivalent 

    2. Install the 2 O-rings on the air conditioning tube assy.
    3. 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) 

    Fig 34: Installing Air Conditioning Tube Assy
    G02609931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. TEMPORARILY TIGHTEN AIR CONDITIONING UNIT ASSY 
    1. Temporarily tighten the air conditioning unit assy with the nut.

      Torque: 9.8 N.m (100 kgf.cm, 87 in..lbf) 

    2. Install the 2 clamps.
    Fig 35: Installing Clamps
    G02609932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSTALL INSTRUMENT PANEL REINFORCEMENT 
    1. Install the instrument panel reinforcement with the 10 bolts.
      Fig 36: Installing Instrument Panel Reinforcement
      G02609933Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 13 clamps.
    3. Connect the connectors.
    4. Install the 6 nuts.

    Torque: 7.3 N.m (74 kgf.cm, 65 in..lbf) 

    Fig 37: Installing Nuts
    G02609934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL AIR CONDITIONING UNIT ASSY 
    1. Install the air conditioner unit assy with the 3 bolts and 2 nuts.
    Fig 38: Installing Air Conditioner Unit Assy
    G02609935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSTALL SHIFT LOCK CONTROL UNIT ASSY (See  OVERHAUL  ) 
  49. CONNECT TRANSMISSION CONTROL CABLE ASSY (See  OVERHAUL  ) 
  50. INSTALL STEERING COLUMN ASSY (See  OVERHAUL  ) 
  51. INSTALL INSTRUMENT PANEL SUB-ASSY W/PASSENGER AIRBAG ASSY (See  REPLACEMENT  ) 
  52. INSTALL SUCTION HOSE SUB-ASSY 
    1. Lubricate a new O-ring with compressor oil and install it on the hose.

      Compressor oil: ND-OIL 8 or equivalent 

    2. Install the suction hose sub-assy and the piping clamp.

    HINT:

    After the connection, check the claw fitting of the piping clamp.

    Fig 39: Lubricating New O-Ring With Compressor Oil
    G02609936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. INSTALL COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) 
    1. Lubricate a new O-ring with compressor oil and install it to the pipe.

      Compressor oil: ND-OIL 8 or equivalent 

    2. Install the cooler refrigerant liquid pipe E and the piping clamp.

    HINT:

    After the connection, check the claw fitting of the piping clamp.

  54. ADJUST SHIFT LEVER POSITION (See  ADJUSTMENT  ) 
  55. INSPECT SHIFT LEVER POSITION (See  ADJUSTMENT  ) 
  56. INSPECT CHECK KEY INTERLOCK OPERATION (See  SHIFT LOCK SYSTEM  ) 
  57. INSPECT CHECK SHIFT LOCK OPERATION (See  SHIFT LOCK SYSTEM  ) 
  58. INSPECT CHECK SHIFT LOCK RELEASE BUTTON OPERATION (See  SHIFT LOCK SYSTEM  ) 
  59. ADD COOLANT (See  ENGINE COOLANT  ) 
  60. CHARGE REFRIGERANT (See  REPLACEMENT  ) 

    SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)

    Specified amount: 780 +/- 30 g (27.5 +/- 1.06 oz.) 

  61. WARM UP ENGINE 
  62. CHECK FOR ENGINE COOLANT LEAKS (See  COOLING SYSTEM  ) 
  63. INSPECT LEAKAGE OF REFRIGERANT (See  REPLACEMENT  ) 
scientia non olet · About LEMON Manuals