Operation CHARM: Car repair manuals for everyone.
Home >> Lexus >> 2004 >> GX 470 V8-4.7L (2UZ-FE) >> Repair and Diagnosis >> Heating and Air Conditioning >> Technical Service Bulletins >> Customer Interest >> Canada - A/C - A/C Low Cooling Effect In High Temperatures >> Repair Procedure - Install Interior Parts - Steps 16 - 30

Repair Procedure - Install Interior Parts - Steps 16 - 30





16. Install the headlamp hole seal LH.

Before November 2004 production:

A. Using Seal, Radiator Side LH (P/N: 53286-60080) as a template, locate the reference nut shown in the illustration.
B. Align the seal to the headlamp hole area.
C. Using the seal as a template, center punch the three (3) locations shown in the illustration.
D. Drill three (3) 7 mm (0.28 in.) holes in the punch locations shown in the illustration.





From December 2004 to January 2006 production:

A. Using Seal, Radiator Side LH (P/N: 53286-60080) as a template, locate the reference nut shown in the illustration.
B. Align the seal to the headlamp hole area.
C. Using the seal as a template, center punch two (2) holes at positions 1 and 2 shown in the illustration.
D. Drill two (2) 7 mm (0.28 in.) holes in the punch location positions 1 and 2 shown in the illustration.






17. Using the clip, install the Seal, Radiator Side LH.

Seal, Radiator Side LH: P/N 53286-60080






18. Install the wire harness protector.
A. Apply the protector to the left fog lamp wire harness.
B. Attach tape to the wire harness to ensure that the insulator does NOT move.

Insulator Piping: P/N 88714-60280

19. Install the A/C pipe grommet.






Install the rubber grommet to the dash panel.






20. Temporarily install the accessory air conditioner tube assembly (install it from right side of the engine compartment).






21. Install the accessory air conditioner tube assembly by connecting with the 2 quick joints.






22. Install the bolt for the condenser line bracket (front side).






23. Install the accessory air conditioner tube assembly.
A. Install the nut (right side).

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

B. Install the bolt (left side).

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






24. Connect the quick joints on the accessory air conditioner tube assembly.






25. Install the A/C discharge hose sub-assembly (condenser side) by tightening the nut.

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






26. Apply seal packing to the hole for the A/C pipe in the right radiator support.
A. Apply seal packing through the front side of the radiator support to fill in the hole.

Seal Packing: P/N 36867-60010

NOTE:
- Do NOT reuse the pipe and seal that was removed from step 20 of the "Remove exterior parts" section of the Repair Procedure.
- Using the scraper (or equivalent), remove the remaining seal.






27. Connect the wire harness to the A/C pressure switch by engaging the wire harness clip.






28. Install the A/C cooler refrigerant suction hose subassembly.
A. Put the suction hose in from the lower side.
B. Temporarily install the suction hose to the compressor.






C. Install the nut on the A/C cooler refrigerant suction hose sub-assembly (compressor side) from the upper cover in the left wheel well.

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






NOTE:
Some compressors will need to have the A/C cooler refrigerant suction hose retaining stud moved from "A" to "B" as shown.
Torque: 9.8 N-m (100 kgf-cm, 87 in.-lbf)






29. Install the upper clip on the front fender apron seal LH (in left wheel well) by engaging the two (2) upper clips on front fender apron seal.

NOTE:
Kinetic suspension fender apron will slightly differ in configuration based on model year.






30. Install the A/C cooler refrigerant suction hose subassembly from under the vehicle working your way up into the engine compartment Tighten the bolt.

Torque: 5.4 N-m (55 kgf-cm, 48 in.-lbf)
pro multis · About Operation CHARM