A/c-Heater System: Removal & Installation Lexus GS II

REMOVAL & INSTALLATION

Tape end of screwdriver and pry center register (No. 2) from instrument panel and disconnect electrical connector. (Scheme 4) Pry cluster finish panel from center console and disconnect electrical connectors. Remove 2 bolts and 2 screws, disconnect electrical connector, then remove radio and A/C control assembly as a unit. Separate radio from A/C control assembly. To install, reverse removal procedure.

1. Disable air bag system. See AIR BAG RESTRAINT SYSTEM article. Tape end of screwdriver and pry right under cover (No. 2) from instrument panel. (Scheme 4) Remove 2 bolts from under glove box panel assembly. Open glove box door. Remove air bag connector plate from upper left corner of glove box. Remove air bag connector from plate.
2. Remove 3 screws and glove box panel assembly. Remove air filter cover from blower unit and remove air filter. To install, reverse removal procedure.

Remove right front door scuff plate. Remove right cowl side trim. Remove right lower instrument panel under cover (No. 2). (Scheme 4) Remove glove box panel assembly. Disconnect electrical connector and remove bracket adjacent to servomotor. Disconnect servo motor connector, remove 3 screws and remove servo motor. (Scheme 2) To install, reverse removal procedure.

Removal & Installation (Driver Side)

Remove left instrument panel under cover (No. 1) and safety pad (No. 1). (Scheme 4) Disconnect servomotor connector, remove 3 screws and remove servo motor. (Scheme 3) To install, reverse removal procedure.

Removal & Installation (Passenger Side)

Remove heater core. See HEATER CORE. Disconnect servomotor connector, remove 3 screws and remove servo motor. (Scheme 3) To install, reverse removal procedure.

Remove right front door scuff plate. Remove right cowl side trim. Remove right lower instrument panel under cover (No. 2). (Scheme 4) Remove glove box panel assembly. Remove air duct on right side of cooling unit. Disconnect servomotor connector, remove 2 screws and remove servo motor. (Scheme 3) To install, reverse removal procedure.

Remove right front door scuff plate. Remove right cowl side trim. Remove right lower instrument panel under cover (No. 2). (Scheme 4) Disconnect blower motor electrical connector. Remove 3 screws and blower motor. To install, reverse removal procedure.

Remove right front door scuff plate. Remove right cowl side trim. Remove right lower instrument panel under cover (No. 2). (Scheme 4) Remove glove box panel assembly. Remove small air duct on right side of cooling unit. Remove screw and blower motor control relay, then disconnect electrical connector. To install, reverse removal procedure.

1. Disconnect negative battery cable. Remove instrument panel. See «INSTRUMENT PANEL»(ref-125255-S26108365042001100400000). Disconnect wire connector located above air duct. (Scheme 2) Remove 3 screws and air duct. Release claw of wire harness connector bracket and disconnect connector bracket. Disconnect wire harness retaining clamp and disconnect wire harness.
2. Remove 2 bolts and remove blower unit bracket. Remove bolt, screw and nut and remove blower unit. To install, reverse removal procedure.

Scheme 2

1. If compressor runs, idle engine for 10 minutes with A/C on. Turn ignition off. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Raise and support vehicle. Remove engine under cover. Remove drive belt. Unplug compressor connector. Disconnect and cap refrigerant hoses from compressor.
2. On GS300, remove 2 power steering pump set bolts and power steering pump. Remove power steering pump bracket. Remove compressor bracket. Remove compressor bolts and compressor. On GS400, remove bolt, nut an compressor stay. Remove compressor bolts and compressor.
3. To install, reverse removal procedure. Evacuate and charge A/C system. Inspect system for leaks.

1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect and plug refrigerant lines from evaporator. Drain cooling system and disconnect heater hoses from heater core water pipes.
2. Remove heater pipe and drain hose grommets. Remove instrument panel. See «INSTRUMENT PANEL»(ref-125255-S26108365042001100400000). Remove blower unit. See «BLOWER UNIT»(ref-125255-S05827316952001100400000). Remove console box duct (No. 1). Slide carpet rearward and disconnect wire harness clamps located along side of right floor air duct. Remove right and left floor air ducts. Unplug wiring harness and remove cooling unit.
3. Disassemble cooling unit. Replace components as necessary. (Scheme 3) To install, reverse removal procedure. Evacuate and charge A/C system. Inspect system for leaks.

Scheme 3

1. Remove cooling unit. See «COOLING UNIT»(ref-125255-S25465348372001100400000). Remove heater core water pipe clamp. Pull heater core from right side of cooling unit. (Scheme 3)
2. Remove passenger side air mix servomotor. Using Expansion Valve Wrench Set (07117-61050), separate tube and accessory together with expansion valve from evaporator. (Scheme 3) Remove evaporator drain pipe.
3. Disconnect blower motor control relay electrical connector. Remove 4 screws and remove evaporator cover from right side of cooling unit. Pull evaporator from cooling unit.
4. To install, reverse removal procedure. Refill cooling system. Start and warm engine to operating temperature. Evacuate and charge A/C system. Inspect system for leaks.

Remove left instrument panel under cover (No. 1). (Scheme 4) Remove hood latch lever and left instrument panel safety pad (No. 1). Disconnect sensor electrical connector. Tape end of screwdriver and remove evaporator temperature sensor and bracket plate from left side of cooling unit. Release 2 claws and remove sensor from bracket plate. To install, reverse removal procedure.

Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect and plug refrigerant lines from evaporator. Remove instrument panel. See INSTRUMENT PANEL . Remove packing from expansion valve. Using Expansion Valve Wrench Set (07117-61050), separate expansion valve and tube and accessory. To install, reverse removal procedure. Evacuate and charge A/C system. Inspect system for leaks.

1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect and plug refrigerant lines from evaporator.
2. Drain cooling system and disconnect heater hoses from heater core water pipes. Remove heater pipe and drain hose grommets. Remove instrument panel. See «INSTRUMENT PANEL»(ref-125255-S26108365042001100400000). Remove blower unit. See «BLOWER UNIT»(ref-125255-S05827316952001100400000). Remove console box duct (No. 1).
3. Slide carpet rearward and disconnect wire harness clamps located along side of right floor air duct. Remove right and left floor air ducts. Unplug wiring harness and remove cooling unit. Remove heater core water pipe clamp. Pull heater core from right side of cooling unit. (Scheme 3)
4. To install, reverse removal procedure. Refill cooling system. Start and warm engine to operating temperature. Inspect system for leaks. Evacuate and charge A/C system. Inspect system for leaks.

Removal

1. Disable air bag system. See AIR BAG RESTRAINT SYSTEM article. Disconnect negative battery cable. Remove front pillar garnishes. Remove front door scuff plates. (Scheme 4) Remove steering wheel pad (driver-side air bag module). Remove steering wheel nut. Mark steering wheel and shaft for reassembly reference. Remove steering wheel.
2. Remove upper and lower steering column covers. Remove combination switch. Tape end of screwdriver and pry ignition switch end pad from instrument panel. Remove left instrument panel under cover (No. 1). Remove hood latch lever and left instrument panel safety pad (No. 1). Remove parking brake handle. Remove switch hole base (No. 1).
3. Remove 4 nuts and steering column. Tape end of screwdriver and pry instrument cluster finish panel from instrument panel. Remove 4 screws then remove instrument cluster and disconnect electrical connectors. Tape end of screwdriver and pry right under cover (No. 2) from instrument panel.
4. Open glove box door. Remove air bag connector plate from upper left corner of glove box. Remove air bag connector from plate and disconnect air bag connector. Remove glove box panel assembly. Remove 3 nuts, disconnect electrical connector and remove CD changer. Remove ashtray.
5. Tape end of screwdriver and pry center register (No. 2) from instrument panel and disconnect electrical connector. Pry cluster finish panel from center console and disconnect electrical connectors. Remove 2 bolts and 2 screws, disconnect electrical connector then remove radio together with A/C control assembly as a unit.
6. Remove console box carpet and lower console box. Remove rear console arm rest. Remove console box mounting bracket an remove console. Remove console box duct (No. 1). Remove heater-to-register duct (No. 7). Remove 5 bolts, nut and screw then remove instrument panel. Remove brace No. 1 and 2. Remove 5 nuts and 4 bolts then remove reinforcement.

Installation

To install, reverse removal procedure. Tighten steering wheel pad Torx screws and steering wheel hub nut to specification. See TORQUE SPECIFICATIONS . Reactivate air bag system. See procedures in AIR BAG RESTRAINT SYSTEM article.

Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Hold pressure switch mount with open end wrench. Being careful not to deform tube, remove pressure switch. To install, lubricate new "O" ring with compressor oil then reverse removal procedure. Evacuate and charge A/C system. Inspect system for leaks.

Scheme 4