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Please help! I own a 2001 Lexus 300ES and have to find an affordable "fix" to solve a toxic cabin air problem--or sell the car. There are no other mechanical problems so I'd love to keep it. First, I've had the clumps of black foam/insulation coming out of the vents off and on for about a year. Before that, I had and still have a problem with the recirculate feature not working. I can switch the recirculate button back and forth, but still can smell outside air (diesel, gasoline, etc.) in the recirculate position. Several times over the past few years, I've gotten terribly ill with bad sore throat, congestion, etc., after a long drive. I attribute this to toxic air coming into the cabin. But how? and from where? The engine compartment? Please help guys. --Lexus Lady in Baton Rouge
I know this is an old thread, and that my information is based on a 2010 RX350, but I think that it might be helpful to someone. I noticed pieces of foam coming out of my AC vents a few weeks ago, and have now had the time to investigate. Found out that the foam is around the baffle inside the vent that allows it to be shut off. My wife has recently been shutting hers off on the passenger side. Now I can see chunks of it missing around each vent that she tuned off and back on. I would have liked to have had Lexus use better materials, but am not going to worry about it; it's not worth the expense and time of replacing it. I will just deal with a little air coming out even with the vent tuned off.
Bumping a necro thread for more exposure. My IS F spit out a chunk of foam exactly as described by the OP in this thread yesterday. I have practical experience with this problem, as my 30 year old Supra did the same thing, and I ended up removing the dash, support bar, and HVAC unit to replace all the foam inside the HVAC control box. This box is the same box all the other LHD 2IS cars use, so I am wondering now if there is anyone making foam replacement kits for these like there is for the MkIV Supra.