Lexus ES300 (1997 year). Service manual - part 35

AC09Q–01

N21067

N20237

Heater Radiator Pipe

Water Hose

Hose Clip

45 

±

 10

°

Lower

Upper

RH

LH

Marking

–

AIR CONDITIONING

AIR CONDITIONING UNIT

AC–23

1580

1997 LEXUS ES300   (RM511U)

REMOVAL

1.

DISCHARGE REFRIGERANT FROM REFRIGERATION
SYSTEM

HINT:
At the time of the installation, please refer to the following item.
Evacuate air from refrigeration system.
Charge system with refrigerant and inspect for leakage of refrig-
erant.

Specified amount: 800 

±

 50 g (28.22 

±

 1.76 oz.)

2.

DRAIN ENGINE COOLANT FROM RADIATOR

HINT:
It is not necessary to drain out all the coolant.

3.

DISCONNECT WATER VALVE CONTROL CABLE
FROM WATER VALVE

HINT:
At the in time of the installation, please refer to the following
item.
For installing the control cable, refer to ”INSTALLATION” of
”WATER VALVE” on page 

AC–60

.

4.

DISCONNECT WATER HOSES FROM HEATER RA-
DIATOR PIPES

(a)

Using pliers, grip the claw of the hose clip and slide the
hose clip along the hose.

(b)

Disconnect the water hoses.

HINT:
At the time of the installation, please refer to the following items.

Push the water hose onto the heater radiator pipe as far
as the pipe grommet and install the hose clip.

Install the hose clip in a position, as shown in the illustra-
tion.

N21063

N21065

AC–24

–

AIR CONDITIONING

AIR CONDITIONING UNIT

1581

1997 LEXUS ES300   (RM511U)

5.

REMOVE THESE PARTS:

(a)

Blower unit (See page 

AC–29

)

(b)

Instrument panel and reinforcement (See page 

BO–82

)

6.

DISCONNECT LIQUID AND SUCTION TUBES

Remove the bolt and slide the plate, then disconnect both
tubes.

Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)

NOTICE:
Cap the open fittings immediately to keep moisture or dirt
out of the system.
HINT:
At the time of the installation, please refer to the following item.
Lubricate 2 new O–rings with compressor oil and install the
tubes.

7.

REMOVE A/C UNIT

(a)

Slide the floor carpet backward.

(b)

Remove the rear heater ducts.

(c)

Disconnect the connectors.

(d)

Remove the 2 nuts and A/C unit.

AC09R–01

–

AIR CONDITIONING

AIR CONDITIONING UNIT

AC–25

1582

1997 LEXUS ES300   (RM511U)

DISASSEMBLY

1.

REMOVE THESE PARTS:

(a)

Side air ducts LH, RH

(b)

Foot air ducts LH, RH

2.

REMOVE EVAPORATOR TEMP. SENSOR

Remove the screw and pull out the sensor.
3.

REMOVE EVAPORATOR

(a)

Remove the 6 screws and evaporator cover.

HINT:
At the time of reassembly, please refer to the following item.
Do not reuse the evaporator cover.
(b)

Pull out the evaporator.

HINT:
At the time of reassembly, please refer to the following item.
If evaporator is replaced, add compressor oil to evaporator.

Add 40 cc (1.4 fl.oz.)
Compressor oil: ND–OIL 8 or equivalent

4.

REMOVE EXPANSION VALVE

Using a hexagon wrench, remove the 2 bolts and separate the evaporator and expansion valve.

Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)

HINT:
At the time of reassembly, please refer to the following item.
Lubricate 4 new O–rings with compressor oil and install the valve.
5.

REMOVE AIR MIX SERVOMOTOR

(a)

Remove the 3 screws and servomotor.

(b)

Remove the water valve control cable from the servomotor.

6.

REMOVE AIR OUTLET SERVOMOTOR

Remove the 2 screws and servomotor.
7.

REMOVE HEATER RADIATOR

(a)

Release the 3 claws and remove the heater protector.

(b)

Remove the 2 screws and 2 clamps, then pull out the heater radiator.

(c)

Remove the 2 screws, 2 clamps and heater radiator pipes from the heater radiator.

8.

REMOVE BLOWER RESISTOR

(a)

Disconnect the connector.

(b)

Remove the 2 screws and blower resistor.

9.

REMOVE BLOWER MOTOR LINEAR CONTROLLER

(a)

Disconnect the connector.

(b)

Remove the 2 screws and blower motor linear controller.

10.

REMOVE WIRE HARNESS

Release the claw and remove the wire harness.

AC09T–01

AC–26

–

AIR CONDITIONING

AIR CONDITIONING UNIT

1583

1997 LEXUS ES300   (RM511U)

REASSEMBLY

Reassembly is in the reverse order of disassembly (See page 

AC–25

).