evap LEXUS SC400 1991 Service User Guide

EVAPORATOR
REMOVAL OF EVAPORATOR
1. DISCONNECT NEGATIVE (±) CABLE FROM BATTERY
2. RECOVER REFRIGERANT IN REFRIGERATION SYSTEMSee page AC±16
3. REMOVE ABS ACTUATOR
See page BR±48
4. REMOVE LIQUID TUBE AND SUCTION TUBE Remove two bolts and both tubes.
5. REMOVE EQUALIZER TUBE FROM EPR
Remove the bole and the tube.
NOTICE: Cap the open fittings immediately to keep mois-
ture out of the system.
6. REMOVE UNDER COVER GLOVE BOX AND SIDE AIR DUCT
7. DISCONNECT CONNECTORS AND REMOVE POWER STEERING RELAY BOX COOLING FAN COMPUTER AND
TRC COMPUTER
AC±122
±
AIR CONDITIONING SYSTEM Evaporator
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8. PULL FLOOR CARPET DOWN AND REMOVECOMPUTER COVER
9. REMOVE EVAPORATOR COVER AND FOOT AIR DUCT BOLT
10. REMOVE EVAPORATOR (a) Remove six bolts and down the lower case.
(b) Pull and remove the evaporator.
(c) Pull out the evaporator sensor from the evaporator fins.
(d) Remove two bolts using a hexagon wrench and separate the evaporator and expansion valve.
INSPECTION OF EVAPORATOR
1. INSPECT FINS FOR BLOCKAGE
If the fins are clogged, clean them with compressed air.
NOTICE: Never use water to clean the evaporator.
2. INSPECT FITTINGS FOR CRACKS OR SCRATCHES Repair as necessary.
±
AIR CONDITIONING SYSTEM EvaporatorAC±123
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INSTALLATION OF EVAPORATOR
1. INSTALL REMOVAL PARTSInstall the removal parts in reverse order of removal proce-
dure.
HINT:
wThe tightening torque for the bolt used to install the
expansion valve on the evaporator is shown below.
Specified torque: 5.4 N Vm (55 kgf Vcm, 48 ft Vlbf)
w The tightening torque for the bolts used to install the
liquid tube and suction tube to the cooling is shown
below.
Specified torque: 10 N Vm (100 kgf Vcm, 7 ft Vlbf)
w The tightening torque specified for the bolt used to
install the equalizer tube to EPR is shown below.
Specified torque: 25 N Vm (250 kgf Vcm, 18 ft Vlbf)
2. IF EVAPORATOR WAS REPLACED, ADD COMPRESSOR
OIL TO EVAPORATOR
Add 40±50 cc (1.4±1.7 fl.oz)
Compressor oil: ND OIL 6,
SUNISO NO. 5 GS or equivalent
3. EVACUATE AIR IN REFRIGERATION SYSTEM ANDCHARGE WITH REFRIGERANT
Specified amount: 950 + 50 g (33.44 + 1.76 oz)
4. INSPECT FOR LEAKAGE OF REFRIGERANT
Using a gas leak tester, check for leakage of refrigerant.
AC±124
±
AIR CONDITIONING SYSTEM Evaporator
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EXPANSION VALVE
ON±VEHICLE INSPECTION
1. CHECK QUANTITY OF GAS DURING REFRIGERATIONCYCLE
2. INSTALL MANIFOLD GAUGE SET
3. RUN ENGINE
Run the engine at 2,000 rpm for at least 5 minutes. Then
check that the high pressure reading is 1,275±1,471 kPa
(13±15 kgf/cm, 185±213 psi).
4. CHECK EXPANSION VALVE If the expansion valve is faulty, the low pressure reading will
drop to 0 kPa (0 kgf/cm, 0 psi), otherwise it is OK.
HINT: When the low pressure drops to 0 kPa (0 kgf/cm, 0 psi),
feel the receiver's IN and OUT sides for no temperature differ-
ence.
REMOVAL OF EXPANSION VALVE
1. REMOVE EVAPORATOR See page AC±124.
2. REMOVE EQUALIZER TUBES
3. REMOVE EXPANSION VALVE
INSTALLATION OF EXPANSION VALVE
1. INSTALL EXPANSION VALVE
Specified torque:
0.31 inch tube 13 N Vm (135 kgf Vcm, 10 ft Vlbf)
0.50 inch tube 22 N Vm (225 kgf Vcm, 16 ft Vlbf)
2. INSTALL EQUALIZER TUBES
3. INSTALL EVAPORATOR
See page AC±124
AC±126
±
AIR CONDITIONING SYSTEM Expansion Valve
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SOLAR SENSOR
REMOVAL OF SOLAR SENSOR
1. REMOVE NO. 1 DEFROSTER GARNISHSee page BO±109
2. REMOVE SENSOR Push out the sensor from the garnish.
INSPECTION OF SOLAR SENSOR
See page AC±52
INSTALLATION OF SOLAR SENSOR
1. INSTALL SENSOR TO NO. 1 DEFROSTER GARNISH
2. INSTALL NO. 2 DEFROSTER GARNISH
See page BO±109
EVAPORATOR TEMPERATURE
SENSOR
REMOVAL OF EVAPORATOR
TEMPERATURE SENSOR
1. REMOVE EVAPORATOR
See page AC±122
2. REMOVE SENSOR FROM EVAPORATOR
INSPECTION OF EVAPORATOR
TEMPERATURE SENSOR
See page AC±48
INSTATION OF EVAPORATOR
TEMPERATURE SENSOR
1. INSTALL SENSOR TO EVAPORATOR
2. INSTALL EVAPORATOR
See page AC±124
AC±134
±
AIR CONDITIONING SYSTEM Solar Sensor, Evaporator Temperature Sensor
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SERVICE SPECIFICATIONS
SERVICE DATA
Idle speed Magnetic clutch no engaged
Magnetic clutch engaged
Magnetic clutch clearanceApprox. 700 rpm
Approx. 700 rpm
0.5 + 0.15 mm 0.020 + 0.006 in.
TORQUE SPECIFICATIONS
Part tightenedN Vmkgf Vcmft Vlbf
Suction hose X Compressor2525018
Discharge hose X Compressor25250 18
Compressor X EngineBolt 49500 36
Nut 29300 22
Liquid tube X Receiver10 55 7
Liquid tube X Condenser10100 7
Discharge tube X Condenser10100 7
Expansion valve X Evaporator 5.4 55 48 in. Vlbf
Suction tube X A/C Unit10100 7
Liquid tube X A/C Unit10100 7
Equalizer tube X EPR25250 18
Pressure switch X Liquid tube10100 7
±
AIR CONDITIONING SYSTEM Service SpecificationsAC±139
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10. REMOVE LH ENGINE WIRE COVERRemove the two bolts and engine wire cover.
11. REMOVE VSV FOR EVAP SYSTEM Remove the two bolts, and disconnect the VSV from cylinder
head and timing belt cover.
12. REMOVE RH NO.3 TIMING BELT COVER Remove the three bolts and timing belt cover.
13. REMOVE LH NO.3 TIMING BELT COVER (a) Remove the four mounting bolts.
(b) Disconnect the cord grommet from the timing belt cover,
and remove the timing belt cover.
(c) Remove the cord grommet from the high±tension cord.
14. DISCONNECT RADIATOR HOSE FROM WATER INLET
15. REMOVE DRIVE BELT IDLER PULLEY Remove the pulley bolt, cover plate and idler pulley.
±
COOLIING SYSTEM Electronically Controlled Hydraulic
Cooling Fan (Hydraulic Pump)CO±29
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5. INSTALL DRIVE BELT IDLER PULLEYInstall the idler pulley and cover plate with the pulley bolt.
Torque: 37 N Vm (380 kgf Vcm, 27 ft Vlbf)
6. CONNECT RADIATOR HOSE TO WATER INLET
7. INSTALL RH NO.3 TIMING BELT COVER
(a) Install the three gaskets to the timing belt cover.
(b) Fit portion A of the timing belt cover, matching it with the
lower high±tension cord cover.
(c) Install the timing belt cover with the three bolts.
8. INSTALL VSV FOR EVAP SYSTEM Install the VSV with the two bolts.
9. INSTALL LH NO.3 TIMING BELT COVER (a) Install the three gaskets to the timing belt cover.
(b) Install the cord grommet to the high±tension cord.
(c) Install the cord grommet to the timing belt cover.
(d) Fit portion A of the timing belt cover, matching it with the
lower high±tension cord cover.
(e) Install the timing belt cover with the four bolts.
10. INSTALL RH ENGINE WIRE COVER (a) Fit portions A and B of the engine wire cover, matchingthem with the lower high±tension cord cover and No.3
timing belt cover.
(d) Install the engine wire cover with the bolt.
±
COOLIING SYSTEM Electronically Controlled Hydraulic Cooling Fan
(Hydraulic Pump)CO±43
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SERVICE SPECIFICATIONS
SPECIFICATIONS
VSV (For EVAP) Resistance30±34

VSV (For EGR)Resistance33±39

TORQUE SPECIFICATIONS
Part tightenedN mkgf cmftVlbf
VSV for EGR X Intake manifold18185 13
EGR valve X Intake manifold18185 13
EGR valve X EGR Pipe64650 47
Catalytic converter (Front) X Exhaust manifold62630 46
Catalytic converter (Front) X Front Exhaust pipe43440 32
Front exhaust pipe X Center exhaust pipe43440 32
Sub±oxygen sensor X Front exhaust pipe1818013
EC±20±
EMISSION CONTROL SYSTEMS Service Specifications
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SERVICE SPECIFICATIONS
SERVICE DATA
VSVResistance30±34

for EVAP
VSVResistance33±39

for EGR
EGR valveResistance19.9±23.4

(CALIF. only)
TORQUE SPECIFICATIONS
Part tightenedNVmkgf Vcmft Vlbf
VSV for EGR X Air intake chamber (Exc. USA Spec.)1818513
EGR valve X Air intake chamber18185 13
Catalytic converter (Main) X Exhaust manifold62630 46
Catalytic converter (Main) X Front exhaust pipe43440 32
Front exhaust pipe support bracket X Transmission43440 32
Front exhaust pipe X Center exhaust pipe43440 32
Main oxygen sensor X Front exhaust pipe4445033
EC±30±
EMISSION CONTROL SYSTEMS Servuce Specifications
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