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Home >> Lexus >> 2005 >> GX 470 V8-4.7L (2UZ-FE) >> Repair and Diagnosis >> Maintenance >> Technical Service Bulletins >> All Technical Service Bulletins >> A/C - Poor Cooling Performance >> Repair Procedure >> Install Interior Parts

Install Interior Parts





1. Install the NEW and improved cooler expansion valve.

A. Apply insulator tape to the improved cooler expansion valve.

Tape: Piping Insulator (P/N: 88578-35170)

NOTE:
Do NOT allow tape to protrude over the sides of the improved cooler expansion valve, or a leak could occur.

B. Apply compressor oil to the 2 0-rings on the evaporator lines and the fitting surface of the improved cooler expansion valve.

Compressor oil: ND-01L8
(or equivalent)





C. Install the improved cooler expansion valve to the cooler evaporator sub-assembly No.1 using NEW upper side and lower side 0-rings.

Upper Side: P/N 90099-14121 Lower Side: P/N 90099-14120





2. Install the A/C tube.

A. Apply compressor oil to 2 NEW 0-rings and the fitting surface of the A/C tube assembly.

Compressor oil: ND-OIL8
or equivalent

B. Install the 2 0-rings on the A/C tube assembly.

C. Using a 4 mm hexagon wrench, install the A/C assembly with the 2 bolts and NEW upper side and lower side 0-rings.

Torque: .5 N.m (35 kgf.cm, 30 in.lbs)

Upper Side: P/N 90099-14121

Lower Side: P/N 90099-14120





3. Install the cover plate (expansion valve cover).

A. Install the claw fitting.

B. Install the screw.

CAUTION:
If the hook portion of the upper cover plate is broken during removal, replace the broken hook portion with a NEW one. If the claw is NOT broken, it may be reused.





4. Install the blower assembly.

A. Install the blower assembly with the claw fittings.

a. Slide the blower assembly.

b. Lower down the blower assembly.





B. Install the bolt, the 2 screws, and the nut.

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

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

CAUTION:
^ NOT reuse the broken bolts

^ Be sure to install hardware to secure the air box.





C. Install the 7 clamps and connect the connectors.

NOTE:
Be sure to connect all connectors.





5. Install the 3 claws and install the air duct No.2.

HINT:

For easy installation, engage the upper claws first.





6. Install the disc player changer with the bracket (if equipped).

A. Connect the connectors.

B. Engage the 2 claws and place the disc player changer with the bracket temporarily on the body.

C. Install the 4 bolts and disc player changer with the bracket.

Torque: 5.4 N.m

(55 kgf.cm, 48 in.lbf)





7. Install the glove compartment door assembly.

A. Connect the connectors, install the glove compartment door assembly, and then engage the 2 clips.

B. Engage the 5 screws.

8. Install instrument panel ornament. Engage the 4 clips and the instrument panel ornament.





9. Install the 4WD ECU and the tire pressure monitor ECU to the instrument panel under cover No.2 with 2 screws each.





10. Install the instrument panel under cover No. 2.

A. Engage the 3 clips.

B. Install the screw.





11. Install the tube sub-assembly oil cooler.

A. Install the tube sub-assembly oil cooler.

B. Apply the seal from the LH front side.

Tube Sub-assembly Oil Cooler:

P/N 32906-60230





12. Install the A/T tube sub-assembly oil cooler.

A. Insert the hose to the back of the spool.

B. Install the hose so that the paint colors of the sub-tube and hose match.

C. Install the securing clip to the previous location.

D. After installing the oil cooler tube, add an additional 5 cc to 10 cc of A/T oil to the transmission.





13. Install the A/T oil cooler by tightening all 3 bolts as shown in the illustration.

Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)

14. Prepare the headlamp hole seal RH.

Before November 2004 production:





A. Using Seal, Radiator Side RH (P/N: 53285-60080) as a template, locate the reference nu shown in the illustration.

B. Align the seal to the headlamp hole area.

C. Using the seal as a template, center punch the 3 locations shown in the illustration.

D. Drill three 7-mm (0.28 in.) holes in the punch locations shown in the illustration.

From December 2004 to January 2006 production:

A. Remove the air shield plate (DO NOT REUSE) from the RH headlamp area.





B. Using Seal, Radiator Side RH (P/N: 53285-60080) as a template, locate the reference nut shown in the illustration.

C. Align the seal to the headlamp hole area.

D. Using the seal as a template, center punch 1 hole at the position shown in the illustration.

E. Drill one 7-mm (0.28 in.) hole in the punch location position shown in the illustration.





15. Using the clip, install the Seal, Radiator Side RH.

Seal, Radiator Side RH:
P/N 53285-60080





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 3 locations shown in the illustration.

D. Drill three 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 2 holes at positions 1 and 2 shown in the illustration.

D. Drill 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 NC tube assembly (install it from right side of the engine compartment).





21. Install the accessory A/C tube assembly by connecting with the 2 quick joints.





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





23. Install the accessory A/C 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 A/C 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. 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 NC pressure switch by engaging the wire harness clip.





28. install the A/C cooler refrigerant suction hose sub-assembly.

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 2 upper clips on the front fender apron seal.





30. Install the A/C cooler refrigerant suction hose sub-assembly 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)





31. Install the A/C suction hose sub-assembly by tightening the nut.

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

32. Install the radiator reserve tank by tightening the 3 bolts.

Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)





33. Install the power steering fluid reserve tank by putting the reserve tank in the bracket from the upper side.





34. Install the skid control sensor bracket and connect the wire harness connector (right engine compartment).

A. Install the bracket in the right tire apron.

B. Connect the 2 wire harness connectors.

35. Raise the vehicle.





36. Install the tube sub-assembly heat exchanger and rear A/C tube by tightening the nut.

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





37. Install the tube sub-assembly heat exchanger bracket.





38. Install the front fender apron seal clip by engaging the 2 upper clips on the front fender apron seal.





39. Install the bracket cooler RH and LH by tightening the bolt.

Torque: 47 N.m

(479 kgf.cm, 416 in.lbf)
Bracket Cooler: P/N 88688-6A770
Bolt Hexagon: P/N 90105-12122

NOTE:

^ "L" is marked on the bracket cooler LH.

^ "R" is marked on the bracket cooler RH.





40. Apply seal packing to center position of the front engine under cover sub-assembly.

Seal Packing: P/N 36867-60080





41. Apply seal packing to the right and left of the front engine under cover sub-assembly.

Seal Packing: P/N 36867-60090





42. Install engine under cover sub-assembly No. 1 by tightening the 4 bolts.

Torque: 29 N.m

(296 kgf.cm, 257 in.lbf)





43. Install the engine under cover sub-assembly No.2 by tightening the 4 bolts.

Torque: 29 N.m

(296 kgf.cm, 257 in.lbf)





44. Install the front bumper cover lower by installing the 2 bolts and 2 clips.

45. Lower the vehicle.

46. Apply seal packing to the head lamp assembly RH and LH. Seal Packing: P/N 36867-60060





NOTE:
Fit the edge of the seal to the headlamp as shown in the illustration.





47. Apply seal packing to the headlamp assembly RH and LH as shown in the illustration. Seal Packing: P/N 36867-60070

NOTE:
Fit the edge of the seal to the headlamp as shown in the illustration.





48. Install the front bumper retainer upper center bracket by installing the 2 bolts.





49. Install the front head lamp assembly RH and LH by installing the 3 bolts to each side.





50. Install the front bumper stay No. 2 RH and LH by installing the 2 bolts and 2 nuts.





51. Connect the ground terminal of the engine main wire harness RH by installing the ground cable RH.

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





52. Install the front bumper assembly.

A. Connect the wire harness connector of the fog lamps.

B. Engage the clip in front of the fender liner.

C. Engage the 3 clips and install the 4 bolts and 8 screws.





53. Install the air cleaner assembly.

A. Install the lower air cleaner assembly with the 3 bolts.

B. Install the air cleaner.

C. Install the air cleaner cover.

D. Connect the air cleaner hose and the air cleaner assembly and tighten the band.

E. Connect the throttle w/motor body assembly connector.

F. Install the throttle w/motor body assembly connector bracket.

54. Apply the radiator support seal upper RH and LH.





Refer to the illustration and apply the 2 seals to the back side of the radiator support upper.

NOTE:
Align tape to edge of holes as shown in the illustration.

Seal Packing: P/N 36867-60020 (15x12x55 mm)

Seal Packing: P/N 36867-60030 (15x20x120 mm)





55. Install the radiator support seal upper by engaging the 9 clips.





56. Charge refrigerant HFC-134a (R134a).

A. Vacuum air purge.

For additional information on vacuum air purge, refer to TIS, 2004 model year GX 470 Repair Manual: Heater & Air Conditioner: Air Conditioning System.





B. Charge to 720 g (1.6 lbs) of refrigerant HFC-134a (R134a) and 50 cc of compressor oil.

For additional information on charging refrigerant, refer to TIS, 2004 model year GX 470 Repair Manual: Heater & Air Conditioner: Air Conditioning System.





57. Connect the negative (-) battery cable.
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