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550BL05 AC2810 AC2811 N11084 WrongOkay HILOHILO HEATER & AIR CONDITIONERAIR CONDITIONING SYSTEM 551 4571Author?:Date?: AIR CONDITIONING SYSTEM PRECAUTION 1.DO NOT HANDLE REFRIGERANT IN AN ENCLOSED AREA OR NEAR NAKED FLAME 2.ALWAYS WEAR EYE PROTECTION 3.BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN YOUR EYES OR ON YOUR SKIN If liquid refrigerant gets in your eyes or on your skin: (a)Wash the area with lots of cool water. CAUTION: Do not rub your eyes or skin. (b)Apply clean petroleum jelly to the skin. (c)Go immediately to a physician or hospital for professional treatment. 4.NEVER HEAT THE CONTAINER OR EXPOSE IT TO NAKED FLAME 5.BE CAREFUL NOT TO DROP THE CONTAINER OR APPLY PHYSICAL SHOCKS TO IT 6.DO NOT OPERATE THE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN THE REFRIGERANT SYSTEM If there is not enough refrigerant in the refrigerant system, oil lu- brication will be insufficient and compressor burnout may occur. Necessary care should be taken to avoid this. 7.DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATING If the high pressure valves are opened, refrigerant flows in the reverse direction and could cause the charging cylinder to rup- ture. Open and close only the low pressure valve. 8.BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT If refrigerant is overcharged, it causes problems such as insuffi- cient cooling, poor fuel economy, engine overheating etc. 552 HEATER & AIR CONDITIONERAIR CONDITIONING SYSTEM 4572Author?:Date?: 9.DO NOT OPERATE ENGINE AND COMPRESSOR WITH NO REFRIGERANT CAUTION: Doing so may damage the inside of the compressor be- cause the compressor parts always move regardless of whether the A/C system is turned on or off. 10.SUPPLEMENTAL RESTRAINT SYSTEM (SRS) The LEXUS LS430 is equipped with an SRS (Supplemental Re- straint system) such as the driver, front passenger, side, curtain shield air bags etc Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notices on page 601. 11.PRECAUTION FOR DISCONNECTING THE BATTERY CABLE NOTICE: When disconnecting the negative () battery terminal, ini- tialize the following system after the terminal is recon- nected. System Namesee page Front Power Seat Control System0119 5517E01 I21209 Smog Ventilation Sensor Cooler Condenser Assy Ambient Temperature Sensor Condenser Fan Pressure Switch Smoke Sensor Audio and Rear A/C Control Switch Blower Motor Subassy Rear Air Condition- ing Amplifier Assy Cooling Box Assy Rear Solar Sensor Rear Cooling Unit Expansion Valve Evaporator Subassy (Rear) Exhaust Damper Servomotor Blower Resistor Rear Cooler Filter Cooler Compressor Assy HEATER & AIR CONDITIONERAIR CONDITIONING SYSTEM 553 4573Author?:Date?: LOCATION I21210 A/C Solar Sensor Temperature Control Switch (Passenger side) Duct Sensor (Passenger side) Duct Sensor (Driver side) Intelligent Swing Register Room Temperature Sensor Instrument Cluster Finish Panel Subassy Center Multidisplay (Built in A/C Control Assembly) Rear Cooling Unit Expansion ValveCooler Evaporator Subassy No.1 Air Outlet Servomotor Evaporator Temperature Sensor Cool Air Bypass Servomotor Air Mix Servomotor Air Outlet Servomotor Cool Air Bypass Servomotor Air Inlet Servomotor Heater Radiator Unit Subassy Air Mix Servomotor Water Valve Control Servomotor Clean Air Filter Blower Motor Assy (Cooling Unit Motor Subassy w/ Fan) Air Conditioning Amplifier Assy Temperature Control Switch (Driver side) 554 HEATER & AIR CONDITIONERAIR CONDITIONING SYSTEM 4574Author?:Date?: 5517F01 I18295 Sight Glass HEATER & AIR CONDITIONERREFRIGERANT 555 4575Author?:Date?: REFRIGERANT ONVEHICLE INSPECTION 1.INSPECT REFRIGERANT VOLUME (a)Check the sight glass on the liquid tube. Test conditions: ?Engine is running at 1,500 rpm ?Single A/C: Blower speed control switch at ”HI” position ?Dual A/C: Front blower switch at HI position Rear blower switch at ”HI” position ?A/C switch ON ?Single A/C: Temperature control switch at ”MAX. COOL” position ?Dual A/C: Rear temperature control switch at ”MAX. COOL” position Front driver side temperature control switch at MAX. COOL position Front passenger side temperature control switch at MAX. COOL position ?Fully open the doors ItemSymptomAmount of refrigerantCorrective Actions 1Bubbles existInsufficient* (1) Check for gas leakage and repair if nec- essary (2) Add refrigerant until bubbles disappear 2No bubbles existEmpty, insufficient or excessiveRefer to 3 and 4 3 No temperature difference between com- pressor inlet and outlet Empty or nearly empty (1) Check for gas leakage with gas leak de- tector and repair if necessary (2) Add refrigerant until bubbles disappear 4 Considerable temperature difference be- tween compressor inlet and outlet Proper or excessiveRefer to 5 and 6 5 Immediately after air conditioning is turned off, refrigerant clears Excessive (1) Discharge refrigerant (2) Remove air and supply proper amount of purified refrigerant 6 Immediately after air conditioning is turned off, refrigerant foams and then becomes clear Proper *: Bubbles in the sight glass with ambient temperature higher than usual can be considered normal if cooling is sufficient. E50573 I22117 Condition: Periodically cools and then fails to cool 556 HEATER & AIR CONDITIONERREFRIGERANT 4576Author?:Date?: 2.INSPECT REFRIGERANT PRESSURE WITH MAN- IFOLD GAUGE SET (a)This is a method in which trouble is located by using a manifold gauge set. Read the manifold gauge pressure when these conditions are established. Test conditions: ?Temperature at the air inlet with the switch set at RECIRC is 30 to 35C (86 to 95F) ?Engine is running at 2,000 rpm ?Blower speed control switch is at ”HI” ?Temperature control dial is at ”COOL” HINT: It should be noted that the gauge indications may vary slightly due to ambient temperature conditions. (1)Normally functioning refrigeration system Gauge reading: Low pressure side: 0.15 to 0.25 MPa (1.5 to 2.5 kgf/cm2) High pressure side: 1.37 to 1.57 MPa (14 to 16 kgf/cm2) (2)Moisture present in refrigeration system SymptomProbable causeDiagnosisCorrective Actions During operation, pressure on low pressure side cycles between normal and vacu- um Moisture in refrigeration system freezes at expansion valve orifice, causing a temporary stop of cycle. However, when it melts, normal state is restored. ? Drier in oversaturated state ? Moisture in refrigeration system freezes at expansion valve orifice and blocks circulation of refriger- ant (1) Replace receiver (2) Remove moisture in cycle by repeatedly evacuating air (3) Supply proper amount of new refrigerant I22118 Condition: Cooling system does not function effectively. I22119 Condition: Cooling system does not function effectively. HEATER & AIR CONDITIONERREFRIGERANT 557 4577Author?:Date?: (3)Insufficient cooling SymptomProbable causeDiagnosisCorrective Actions ? Pressure is low on both low and high pressure sides ? Bubbles are continuously seen through sight glass ? Insufficient cooling performance Gas leakage in refrigeration sys- tem ? Insufficient refrigerant ? Refrigerant leaking (1) Check for gas leakage and re- pair if necessary (2) Supply proper amount of new refrigerant (3) If the indicated pressure value is close to 0 when connected to the gauge, create a vacuum after inspecting and repairing the loca- tion of leakage. (4)Poor circulation of refrigerant SymptomProbable causeDiagnosisCorrective Action ? Pressure is low on both low and high pressure sides ? Frost exists on pipe from con- denser to unit Refrigerant flow is obstructed by dirt in the receiver Receiver is cloggedReplace receiver I22120 Condition: Cooling system does not function. (Sometimes it may function.) I22121 Condition: Cooling system does not function. 558 HEATER & AIR CONDITIONERREFRIGERANT 4578Author?:Date?: (5)Refrigerant does not circulate SymptomProbable causeDiagnosisCorrective Actions ? Vacuum is indicated on low pres- sure side and very low pressure is indicated on high pressure side ? Frost or condensation is seen on piping on both sides of receiver/ drier or expansion valve ? Refrigerant flow is obstructed by moisture or dirt in refrigeration sys- tem ? Refrigerant flow is obstructed by a gas leak from expansion valve Refrigerant does not circulate (1) Check heat sensing tube, ex- pansion valve and EPR (2) Clean out dirt in expansion valve by blowing air (3) Replace receiver (4) Evacuate air and charge new refrigerant (5) For gas leakage from expan- sion valve, replace expansion valve (6)Refrigerant is overcharged or cooling effectiveness of condenser is insufficient SymptomProbable causeDiagnosisCorrective Actions ? Pressure is too high on both low and high pressure sides ? No air bubbles are seen through sight glass even when engine rpm lowers ? Unable to develop sufficient per- formance due to excessive use of refrigeration system ? Cooling effectiveness of con- denser is insufficient ? Excessive refrigerant in cycle excessive refrigerant is supplied ? Condenser cooling effectiveness is insufficient condenser fins are clogged at cooling fan (1) Clean condenser (2) Check cooling fan with cooling fan motor operation (3) If (1) and (2) are normal, check the amount of refrigerant and supply proper amount of re- frigerant I22122 Condition: Cooling system does not function. NOTE: These gauge indica- tions occur when the refrigeration system opens and the refrigerant is charged without vacuum purging. I22123 Condition: Insufficient cooling. HEATER & AIR CONDITIONERREFRIGERANT 559 4579Author?:Date?: (7)Air present in refrigeration system SymptomProbable causeDiagnosisCorrective Actions ? Pressure is too high on both low and high pressure sides ? The low pressure piping is too hot to touch ? Bubbles can be seen through sight glass Air in system ? Air present in refrigeration sys- tem ? Insufficient vacuum purging (1) Check compressor oil to see if it is dirty or insufficient (2) Evacuate air and charge new refrigerant (8)Expansion valve malfunction SymptomProbable causeDiagnosisCorrective Actions ? Pressure is too high on both low and high pressure sides ? Frost or large amount of con- densation on piping on low pres- sure side Trouble in expansion valve ? Excessive refrigerant in low pressure piping ? Expansion valve opened too wide (1) Check expansion valve (2) Replace if defective I22124 Condition: Insufficient cooling I30081 0.5 (5.0) 0.4 (4.0) 0.3 (3.0) 0.2 (2.0) MPa (kgf/cm2) Pressure on low pressure side Blower HI Zone Blower LO Zone MPa (kgf/cm2) Pressure on HI pressure side0.5 (5.0)1.0 (10.0)1.5 (15.0)2.0 (20.0) 1.06 (10.80) 0.27 (2.75) 0.22 (2.24) 0.2 (2.03) 0.14 (1.42) 1.2 (12.23) 1.25 (12.74) 1.32 (13.46) 5510 HEATER & AIR CONDITIONERREFRIGERANT 4580Author?:Date?: (9)Defective compression compressor SymptomProbable causeDiagnosisCorrective Action ? Pressure is too high both on low and high pressure sides ? Pressure is too low on high pres- sure side Internal leak in compressor ? Compression failure ? Leakage from damaged valve or broken sliding parts Repair or replace compressor Gauge readings (Reference) 5517G01 I37365 Overcharged Add 170g (6.00 oz.) Height Pressure Refrigerant Amount Point where bubbles disappear ? 50 g (?1.76 oz.) Amount to be charged Subcool system Mean value in proper range HEATER & AIR CONDITIONERREFRIGERANT 5511 4581Author?:Date?: REPLACEMENT 1.DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (a)Turn the A/C switch on. (b)Operate the cooler compressor at an engine rpm of approximately 1,000 for 5 to 6 minutes to circulate the refrigerant and collect as much compressor oil remaining in each component into the cooler com- pressor as possible. (c)Stop the engine. (d)Using SST, discharge refrigerant gas. SST0711058060 (0711758080, 0711758090, 0711778050, 0711788060, 0711788070, 0711788080) 2.CHARGE REFRIGERANT (a)Using a vacuum pump, perform vacuum purging. (b)Using SST, charge refrigerant HFC134a (R134a). Standard: Single A/C: 650 ? 50 g (22.93 ? 1.76 oz.) Dual A/C: 900 ? 50 g (31.74 ? 1.76 oz.) SST0711058060 (0711758060, 0711758070, 0711758080, 0711758090, 0711778050, 0711788060, 0711788070, 0711788080) NOTICE: Do not start the engine before charging with refrigerant as the cooler compressor doesnt work prop- erly without refrigerant, causing the compressor to overheat. 3.WARM UP ENGINE NOTICE: Warm up the engine at less than 2,000 rpm for 2 minutes or more after charging refrigerant. N14519 Drain Hose Gas Leak Detector Front A/C: I19305 Rear A/C: 5512 HEATER & AIR CONDITIONERREFRIGERANT 4582Author?:Date?: 4.INSPECT FOR REFRIGERANT LEAKAGE (a)Perform in these conditions: ?Stop the engine. ?Secure good ventilation (the gas leak detector may not react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas). ?Repeat the test 2 or 3 times. ?Make sure that there is some refrigerant remaining in the refrigeration system. When compressor is off: approx. 392 to 588 kPa (4 to 6 kgf/cm2, 57 to 85 psi) (b)Bring the gas leak detector close to the drain hose before performing the test. HINT: ?After the blower motor has stopped, leave the cooling unit for more than 15 minutes. ?Hold the gas leak detector sensor under the drain hose. ?When bringing the gas leak detector close to the drain hose, make sure that the gas leak detector does not react to volatile gases. If such reaction is unavoidable, the vehicle must be lifted up. (c)If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test. (d)Disconnect the connector and leave the pressure switch for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test. (e)Bring the gas leak detector close to the refrigerant lines and perform the test. (f)Remove the air duct No.2. (g)Using a gas leak detector, check for leakage of refrigerant from evaporator and joint. If there is leakage, check the tightening torque at the joints or evaporator. 5517H01 I18300 Single A/C: Suction Tube Suction Hose Discharge Hose Liquid Tube 10 (100, 7) 5.4 (55, 48 in lbf) Nm (kgfcm, ftlbf): Specified torque 10 (100, 7) 10 (100, 7) HEATER & AIR CONDITIONERREFRIGERANT LINE 5513 4583Author?:Date?: REFRIGERANT LINE COMPONENTS I18301 Dual A/C: 10 (100, 7) Nm (kgfcm, ftlbf): Specified torque 5.4 (55, 48 in lbf) Suction Tube Suction Hose Discharge Hose Liquid Tube 5.4 (55, 48 in lbf) 10 (100, 7) 10 (100, 7) 5514 HEATER & AIR CONDITIONERREFRIGERANT LINE 4584Author?:Date?: 5517I01 I36276 Temperature Control Switch Assy Instrument Cluster Finish Panel Subassy Center Radio Receiver Assembly w/ Bracket Heater Control Bulb Temperature Control Switch Assy Wire Harness Panel Instrument Cluster Finish Lower Integration Panel Finish Panel Lower Center Heater Control Base Bracket No.1 Heater Control Housing Heater Control Base Bracket No.1 Air Conditioner Panel Subassy Intelligent Swing Resistor Assembly Heater Control Base Subassy HEATER & AIR CONDITIONERAIR CONDITIONING PANEL SUBASSY 5515 4585Author?:Date?: AIR CONDITIONING PANEL SUBASSY COMPONENTS 5517K01 H16920 I19307 I19308 I19309 5516 HEATER & AIR CONDITIONERAIR CONDITIONING PANEL SUBASSY 4586Author?:Date?: REPLACEMENT HINT: ?Installation is in the reverse order of removal. ?COMPONENTS: See page 5515. 1.RESTORE SHIP MODE SETTING (W/ CD CHANGER) (SEE PAGE 671) 2.REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER (SEE PAGE 716) 3.REMOVE PANEL INSTRUMENT CLUSTER FINISH LOWER (SEE PAGE 716) 4.REMOVE RADIO RECEIVER ASSEMBLY W/BRACKET (SEE PAGE 675) 5.CONFIRM SHIP MODE (W/ CD CHANGER) (SEE PAGE 671) 6.REMOVE TEMPERATURE CONTROL SWITCH ASSY (a)Using a screwdriver, release the 2 claws and remove the temperature control switch. HINT: Tape the screwdriver tip before use. (b)Employ the same manner described above to the other side. (c)Disconnect the connectors. 7.REMOVE INTEGRATION CONTROL & PANEL ASSY (a)Remove the 2 bolts. (b)Release the 4 claws and remove the integration control & panel assy. 8.REMOVE HEATER CONTROL BASE BRACKET NO.1 (a)Remove the 4 screws and 2 heater control base brackets No.1. I40675 : Claw I40676 : Claw I19311 I40030 : Claw HEATER & AIR CONDITIONERAIR CONDITIONING PANEL SUBASSY 5517 4587Author?:Date?: 9.REMOVE AIR CONDITIONER CONTROL ASSEMBLY (a)Disconnect the connector. (b)Remove the 4 screws, release the 4 claws and remove the air conditioner control assembly. 10.REMOVE HEATER CONTROL HOUSING (a)Remove the 2 screws, release the 4 claws and remove the heater control housing. 11.REMOVE HEATER CONTROL BULB (a)Using a screwdriver, turn the bulbs to the left and pull out the bulbs. 12.REMOVE HEATER CONTROL BASE SUBASSY (a)Release the 4 claws and remove the heater control base. 13.REMOVE AIR CONDITIONER PANEL SUBASSY 5517L01 I36277 Passenger Seat Console Box Air Ducts Heater Water Outlet Hose A Air Conditioning Radiator Assy Blower Assy Drain Hose Console Box Duct No.1 Wire Harness Instrument Panel Safety Pad Subassy Driver Seat Reinforcement VBank Cover Floor Carpet Wire Harness Air Duct Rear No.1 Drain Hose Air Duct Rear No.2 Wire Harness Wire Harness Suction Tube Subassy B Liquid Tube Subassy A 10 (100, 7) Heater Water Inlet Hose B Nm (kgfcm, ftlbf): Specified torque ? Nonreusable part Oring? 5518 HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY 4588Author?:Date?: AIR CONDITIONING RADIATOR ASSY COMPONENTS I18303 Grommet Tube Connector Heater Case Subassy Air Mix Servomotor Water Valve Control Servomotor ?Oring Cooler Expansion Valve ? Oring ?Oring Bracket Air Outlet Servomotor Drain Hose Cool Air Bypass Servomotor Evaporator Temperature Sensor Air Conditioning Tube Assy Evaporator Cover Lower Unit Cas