Automatic A/c-Heater Systems: Removal & Installation Lexus LS III

REMOVAL & INSTALLATION

Removal

1. If compressor operates, idle engine for about 10 minutes with A/C system on. Turn engine off. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment.
2. Disconnect discharge and suction lines from compressor. Cap openings immediately. Raise and support vehicle. Remove engine undercover. Remove drive belt. Disconnect wiring from compressor. Remove ground wire bolt from compressor. Remove nut, 3 bolts, bracket, and compressor.

Installation

To install, reverse removal procedure. See TORQUE SPECIFICATIONS . Evacuate and charge A/C system. Check A/C system for leaks or improper operation.

Using a flat-blade screwdriver with tip taped, remove passenger side undercover. Remove passenger side garnish. Remove finish panel and glove box assembly. Remove air suspension and headlight level control ECU assembly. Remove A/C ECU. Disconnect connectors necessary for removal. To install, reverse removal procedure.

Using a flat-blade screwdriver with tip taped, remove lower center finish panel, lower center cluster finish panel and radio assembly. Using screwdriver, release 4 claws and remove temperature control switches. Remove bolts, release 4 claws and remove center cluster. To install, reverse removal procedure.

Removal & Installation (Driver Side)

Remove driver side undercover. Remove 2 air ducts. Disconnect air mix servomotor connector and remove servomotor. To install, reverse removal procedure.

Removal & Installation (Passenger Side)

Remove blower unit. See BLOWER UNIT . Disconnect water valve control servomotor connector and control cable. Remove water valve control servomotor. Disconnect air mix servomotor connector and remove servomotor. To install, reverse removal procedure.

Remove driver side undercover. Remove 2 air ducts. Disconnect air vent mode servomotor connector and remove servomotor. To install, reverse removal procedure.

Remove blower unit. See BLOWER UNIT . Disconnect air vent mode servomotor connector and remove servomotor. To install, reverse removal procedure.

Remove clip and sensor from right bumper reinforcement. Disconnect harness connector. To install, reverse removal procedure.

Removal & Installation (Front)

Remove glove box assembly and lower panel. Disconnect blower motor connector. Remove 3 screws and blower motor. To install, reverse removal procedure.

Removal & Installation (Rear)

See REAR A/C COOLING UNIT .

Using a flat-blade screwdriver with tip taped, remove passenger side No. 2 undercover. Remove passenger side No. 2 garnish. Remove finish panel and glove box assembly. Remove air suspension and headlight level control ECU assembly. Disconnect connectors necessary for removal. Remove blower unit. (Scheme 4) To install, reverse removal procedure.

Scheme 4

Remove driver side undercover. Remove 2 air ducts. Disconnect servomotor connector. Disconnect control rod and remove servomotor. To install, reverse removal procedure.

Remove blower unit. See BLOWER UNIT . Disconnect servomotor connector and remove servomotor. To install, reverse removal procedure.

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove air cleaner intake hose and air cleaner assembly. Disconnect refrigerant lines from condenser. Cap line openings to prevent contamination.
2. Remove upper radiator mounting brackets, hood lock support, horns and smog sensor. Remove 5 bolts and remove condenser upper support. Remove 3 wiring harness clamps. Push both upper condenser brackets down. Push radiator toward engine. Push condenser toward radiator and pull up to remove.

To install, reverse removal procedure. If installing a new condenser, add 1.4 ounces of refrigerant oil to condenser. Evacuate and charge A/C system. Check A/C system for proper operation.

Drain radiator until coolant level is below upper radiator hose. Remove engine intake air duct and air cleaner assembly. Disconnect upper radiator hose. Disconnect fan connector. Remove 6 bolts and condenser fan assembly. Remove fan electronic control unit. Disconnect wire harness and connector from fan shroud. Remove 3 screws and fan motor. To install, reverse removal procedure.

Remove instrument cluster finish panels. (Scheme 6) Remove instrument cluster. Disconnect instrument cluster connectors. Remove driver side duct sensor from air duct. To install, reverse removal procedure.

Remove finish panel assembly. (Scheme 4) Disconnect appropriate wiring connector. Remove passenger side duct sensor. To install, reverse removal procedure.

Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove instrument panel and reinforcement. See INSTRUMENT PANEL . Pry out expansion valve packing and discard. Using Expansion Valve Separator (07110-61050), remove 4 bolts and separate expansion valve and tube. Discard "O" rings. To install, reverse removal procedure. Lubricate "O" rings with clean refrigerant oil.

Remove instrument panel and reinforcement. See INSTRUMENT PANEL. Using a flat-blade screwdriver with tip taped, remove evaporator temperature sensor from front A/C-heater unit. (Scheme 5) To install, reverse removal procedure.

1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Drain engine coolant until level is below heater core. Completely draining coolant from engine is not necessary. Remove engine "V" bank cover.
2. Disconnect and cap refrigerant lines. Disconnect heater hoses from heater core pipes. Remove grommets. Remove instrument panel. See «INSTRUMENT PANEL»(ref-99101-S11491512482001061800000). Remove blower unit. See «BLOWER UNIT»(ref-99101-S14985704362001061800000). Remove front seats.
3. Remove 3 air ducts. Slide floor carpet backward. Disconnect wiring harness clamp. Remove 2 air ducts. Disconnect A/C unit connectors. Remove drain hose. Remove 2 nuts and a bolt. Remove A/C-heater unit. (Scheme 5)

To install, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS . Refill cooling system and check for leaks. Evacuate and charge A/C system. Check A/C system for leaks or improper operation.

Scheme 5

1. Drain engine coolant until level is below heater core. Completely draining coolant from engine is not necessary. Remove blower unit. See «BLOWER UNIT»(ref-99101-S14985704362001061800000).
2. Remove 3 screws and 3 clamps, and remove heater core pipes. (Scheme 5) Discard "O" rings. Remove heater core. To install, reverse removal procedure. Ensure fittings are not cracked or scratched.

1. Disable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING.Push upper portion of front pillar garnish, then pull and release clip. Discard upper garnish clip. Using a flat-blade screwdriver with tip taped, remove front pillar garnish. (Scheme 6)
2. Remove front door scuff plates. Place front wheels straight-ahead. Remove steering wheel pad (driver air bag). Position steering wheel pad on a clean work bench with pad facing up.
3. Disconnect steering wheel connector. Scribe mating marks on steering shaft and steering wheel. Remove steering wheel, upper and lower steering column covers, combination switch and spiral cable. Remove No. 2 undercover, No. 2 garnish, and finish panel and glove box assembly. Disconnect passenger side air bag.
4. Remove No. 1 undercover and No. 1 safety pad. Remove cluster finish panel. Remove rear console armrest. Remove lower center finish panel. Remove lower cluster finish panel without pulling on door. Remove radio assembly. Remove center cluster finish panel.
5. Remove cluster finish end panel. Remove center lower cluster finish panel. Remove cluster finish panel. Remove console box. Remove 3 instrument cluster screws, disconnect connectors and remove instrument cluster. Remove instrument panel plate.
6. Disconnect instrument panel connectors and release clamps. Remove 2 instrument panel bolts and 4 nuts. Remove 6 instrument panel reinforcement bolts and loosen 3.5" bolt located at end of reinforcement. (Scheme 6) Remove instrument panel with reinforcement.
7. To install, reverse removal procedure. Activate air bag system and verify air bag system is functioning properly. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING.

Scheme 6

Remove No. 1 safety pad from left side of instrument panel. Disconnect aspirator hose and connector from sensor. Remove sensor from instrument panel undercover. To install, reverse removal procedure.

Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect pressure switch harness connector. Remove pressure switch from liquid tube.

To install pressure switch, reverse removal procedure. Evacuate and charge A/C system. Check A/C system for leaks or improper operation.

1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove rear seat cushion and seat back. Remove rear door scuff plates and rear seat side garnishes.
2. Remove rear door opening trim and roof side inner garnishes. Remove package tray trim panel and room partition trim. Remove trunk floor mat. Remove trunk desk side boards. Remove trunk compartment trim.
3. Disconnect and cap refrigerant lines. see scheme 5and (Scheme 7). If equipped with a cool box, remove 4 cool box screws. Remove 5 air ducts. Disconnect electrical connector and remove cooling box light. Remove 2 nuts and 2 bolts, and remove rear A/C cooling unit.
4. Remove air refiner filter. Remove A/C amplifier. Remove rear door servomotor. Remove blower motor resistor. Remove drain hose.
5. If equipped with a cooling box, remove 3 cooling box screws, clip and 2 air ducts. Disconnect connector, remove cooling box light and remove cooling box.
6. Remove smoke sensor. Remove 3 air duct screws and remove air duct. Remove 4 screws and remove cooling unit case. Remove 3 screws and remove blower motor. Remove 4 screws and remove evaporator. Remove expansion valve with magnetic control and cap fittings.

To install, reverse removal procedure. If installing a new evaporator, add 1.4 ounces of refrigerant oil to evaporator. Use new "O" rings lubricated with clean refrigerant oil. Tighten fittings to specification. See TORQUE SPECIFICATIONS . Evacuate and charge A/C system. Check A/C system for leaks or improper operation.

Scheme 7

Remove trunk front cover. Disconnect rear door control servomotor connector. Disconnect expansion valve connector clamp. Remove 3 screws and remove rear door control servomotor. To install, reverse removal procedure.

1. Receiver-drier and filter are located in modulator tank at end of condenser, opposite refrigerant lines. Remove condenser. See «CONDENSER»(ref-99101-S37152202412001061800000) .
2. Position condenser with bottom up. Using a 10-mm hex wrench, remove cap from modulator tank. Remove refrigerant filter. Using pliers, remove drier bag.
3. To install, reverse removal procedure. Install drier bag with folded-over part upward. Insert filter with protrusion facing into modulator tank. Lubricate cap "O" rings with refrigerant oil and install cap. Tighten modulator tank cap to specification. See «TORQUE SPECIFICATIONS»(ref-99101-S17426715832001061800000) .

Using screwdriver with tip taped, pry out solar sensor from instrument panel or rear deck, next to speaker cover (if equipped). Disconnect electrical connector. To install, reverse removal procedure.

Drain engine coolant from radiator until level is lower than water valve. Disconnect water valve control cable. Disconnect coolant hoses from water valve. Remove water valve. To install, reverse removal procedure. Ensure coolant hoses are installed as far as water valve. Refill cooling system.

Remove blower unit. See BLOWER UNIT . Disconnect servomotor connector and control cable. Remove servomotor. To install, reverse removal procedure. Ensure water valve control cable is adjusted correctly. See WATER VALVE CONTROL CABLE under ADJUSTMENTS.