Cooler Condenser ASSY: Overhaul

WARNING: This page is about a different car, the 2004 Lexus LS 430. However, it is still accessible from the selected car via links, so may be relevant.

HINT:

Installation is in the reverse order of removal.
COMPONENTS: See COMPONENTS .

DISCONNECT NEGATIVE TERMINAL CABLE FROM BATTERY
EVACUATE REFRIGERANT HFC-134A (R134A) (SEE REPLACEMENT )
REMOVE AIR CLEANER INLET NO.1 (SEE REPLACEMENT )
REMOVE AIR CLEANER ASSY (SEE REPLACEMENT )
DISCONNECT DISCHARGE HOSE SUB-ASSY NO.1
1. Remove the bolt and disconnect the discharge hose sub-assy No.1 from the condenser assy.
2. Remove the O-ring from the discharge hose sub-assy No.1
  NOTE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
  
  Fig 1: Locating Bolt Discharge Hose Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT LIQUID TUBE SUB-ASSY A
1. Remove the bolt and disconnect the liquid tube sub-assy A from the cooler condenser assy.
2. 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.
  
  Fig 2: Locating Bolt Liquid Tube Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HIGH PITCHED HORN ASSY (SEE HORN SYSTEM )
REMOVE LOW PITCHED HORN ASSY (SEE HORN SYSTEM )
REMOVE SMOG VENTILATION SENSOR
1. Disconnect the connector.
2. Remove the bolt and smog ventilation sensor.
  
  Fig 3: Locating Bolt Smog Ventilation Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HOOD LOCK ASSY
1. Remove the 2 bolts, nut and hood lock assy.
  
  Fig 4: Locating Bolts Hood Lock Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RADIATOR SUPPORT SUB-ASSY UPPER
1. Remove the 2 nuts and 2 radiator brackets.
  
  Fig 5: Locating Nuts Radiator Brackets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 4 bolts and 2 condenser brackets.
  
  Fig 6: Locating Bolts Condenser Brackets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 3 wire harness clamps.
  NOTE: Do not damage the claw of clamp.
  
  Fig 7: Locating Clamps Wire Harness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 4 bolts and radiator support sub-assy upper.
  
  Fig 8: Locating Bolts Radiator Support Sub-Assy Upper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE COOLER CONDENSER ASSY
1. Push down the 2 condenser brackets.
2. Push the radiator toward the engine.
3. Push the condenser toward the radiator and then pull it upward as shown in the illustration.
  
  Fig 9: Pushing Down Condenser Brackets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DRYER
1. Using a hexagon wrench 10 mm (0.39 in.), remove the cap from the modulator.
2. Remove the filter from the modulator.
  
  Fig 10: Removing Cap From Modulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using pliers, remove the dryer.
  
  Fig 11: Removing Dryer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DRYER
1. Insert a new dryer into the modulator.
  NOTE:
  - Do not remove the dryer from its plastic bag until it is ready to be inserted into the modulator.
  - Install the dryer with the 2 layered parts facing upward.
  Fig 12: Inserting Dryer Into Modulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Insert the filter into the modulator.
  NOTE: Install the filter with its protrusion facing downward.
  
  Fig 13: Inserting Filter Into Modulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the cap to the modulator.
1. Apply compressor oil to the O-rings and thread of the cap.
  Compressor oil: ND-OIL 8 or equivalent
2. Using a hexagon wrench 10 mm (0.39 in.), install the caps.
  Torque: 12.3 N.m (125 kgf. cm, 9 ft.lbf)
  
  Fig 14: Locating O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 15: Locating Bolt Liquid Tube Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL LIQUID TUBE SUB-ASSY A
1. Remove the attached vinyl tape from the tube and connecting part of the cooler condenser assy.
2. Sufficiently apply compressor oil to a new O-ring and pipe joint.
  Compressor oil: ND-OIL 8 or equivalent
3. Install the O-ring to the liquid tube sub-assy A.
4. Connect the liquid tube sub-assy A to the cooler condenser assy with the bolt.
  Torque: 5.4 N.m (55 kgf.cm, 48 in. lbf)
INSTALL DISCHARGE HOSE SUB-ASSY NO.1
1. Remove the attached vinyl tape from the tube and connecting part of the cooler condenser assy.
2. Sufficiently apply compressor oil to a new O-ring and hose joint.
  Compressor oil: ND-OIL 8 or equivalent
3. Install the O-ring to the discharge hose sub-assy No.1.
4. Connect the discharge hose sub-assy No.1 to the cooler condenser assy with the bolt.
  Torque: 5.4 N.m (55 kgf.cm, 48 in. lbf)
  
  Fig 16: Locating Bolt Discharge Hose Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT NEGATIVE TERMINAL CABLE TO BATTERY
CHARGE REFRIGERANT (SEE REPLACEMENT )
WARM UP ENGINE
INSPECT FOR REFRIGERANT LEAKAGE (SEE REPLACEMENT )