LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Lexus >> 2007 >> IS 250 AWD >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> Air Conditioning >> Air Conditioning Unit >> Reassembly
July 1: So it begins. Don't worry, this is not in the correct legal jurisdiction!

Air Conditioning Unit: Reassembly

  1. INSTALL COOLER EVAPORATOR SUB-ASSEMBLY 
    1. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the cooler evaporator subassembly.

      Compressor oil: 

      ND-OIL 8 or equivalent 

    2. Install the 2 O-rings on the cooler evaporator subassembly.
      Fig 1: Identifying O-Rings And Cooler Evaporator Subassembly
      G04048418Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the air duct with the 3 claws and 5 screws.
    Fig 2: Identifying Air Duct Claws And Screws
    G04048419Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY 
    1. Install the heater radiator unit sub-assembly.
    2. Install the clamp with the screw.
    Fig 3: Identifying Heater Radiator Unit Sub-Assembly
    G04048420Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL AIR OUTLET CONTROL SERVO MOTOR 
    1. Install the air outlet control servo motor with the 2 screws.
      Fig 4: Identifying Air Outlet Control Servo Motor And Screws
      G04048421Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the drive gear to the air outlet control servomotor. Check that the drive gear and the driven gear are engaged at point with the same number of gear teeth from the standard position. Install the drive gear to the air outlet control servomotor.
    Fig 5: Checking Drive Gear And Driven Gear Engaged Point
    G04048422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, remove the drive gear, adjust the driven gear, and reinstall the drive gear.
    • The number of gear teeth from the standard position varies according to the stop position of the air outlet control servomotor. Make sure that the gears are engaged at a point with the same number of gear teeth from the standard position.
    • If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, the air outlet control servo motor may not operate normally.
  4. INSTALL AIR MIX CONTROL SERVO MOTOR 
    1. Install the air mix control servo motor with the 2 screws.
    2. Install the drive gear to the air mix control servo motor.
    3. Temporarily install the mode damper servo assembly so that the levers fit into each groove.
    4. Slightly lift the air outlet control servo motor. Check that the drive gear and the driven gear are engaged at a point with the same number of gear teeth from the standard position from the view indicated by arrow (A).
      Fig 6: Identifying Air Mix Control Servo Motor And Screws
      G04048423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 7: Identifying Engaged Position Drive Gear And Driven Gear
      G04048424Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, lift the air outlet control servo motor to adjust the driven gear and reinstall the air outlet control servo motor.
      • If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, the air outlet control servo motor may not operate normally.
    5. Install the air outlet control servo motor with the 4 screws.
  5. INSTALL AIR CONDITIONING HARNESS ASSEMBLY 
    1. Attach the 4 clamps to install the air conditioning harness assembly.
    2. Install the air conditioning harness as shown in the illustration.
      Fig 8: Identifying Air Conditioning Harness Connector
      G04048425Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the 2 connectors and attach the clamp.
    Fig 9: Identifying Connectors
    G04048426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL COOLER EXPANSION VALVE 
    1. Install the expansion valve.
    2. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the air conditioning tube assembly.

      Compressor oil: 

      ND-OIL 8 or equivalent 

    3. Install the 2 O-rings on the air conditioning tube assembly.
    4. Using a hexagon wrench 4 mm, install the air conditioning tube assembly with the 2 hexagon bolts.
      Fig 10: Identifying O-Rings And Air Conditioning Tube Assembly
      G04048427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 3.5 N*m (35 kgf*cm, 30 in.*lbf) 

    5. Install a new packing.
  7. INSTALL AIR MIX CONTROL SERVO MOTOR 
    1. Check that the drive gear and the driven gear are engaged at a point with the same number of gear teeth from the standard position. Temporarily install the air mix control servo motor.
      Fig 11: Identifying Air Mix Control Servo Motor
      G04048428Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, remove the air mix control servo motor to adjust the driven gear and reinstall the air mix control servo motor.
      • The number of gear teeth from the standard position varies according to the stop position of the air mix control servo motor. Make sure that the gears are engaged at a point with the same number of gear teeth from the standard position.
      • If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, the air mix control servo motor may not operate normally.
    2. Install the air mix control servo motor with the 3 screws.
  8. INSTALL AIR OUTLET CONTROL SERVO MOTOR 
    1. Install the air outlet control servo motor with the 3 screws.
    2. Connect the connector.
    Fig 12: Identifying Air Outlet Control Servo Motor And Screws
    G04048429Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
scientia non olet · About LEMON Manuals