Automatic A/c-Heater Systems: Removal & Installation Lexus LX J100

REMOVAL & INSTALLATION

Removal & Installation (W/O Navigation System)

1. Using a molding remover, remove 8 center cluster retaining clips, starting with 2 side clips, 3 upper clips and then 3 lower clips. Using a small, flat-blade screwdriver with tip taped, remove all control panel buttons and knobs.
2. Remove 6 rear cover screws and rear A/C amplifier cover. Remove 4 A/C amplifier screws, disconnect connector and remove A/C amplifier. Remove differential lock and hazard switch buttons. Remove screw from rear to remove switch.
3. Remove nut from under temperature control knob on A/C control panel. Remove remaining screws and disconnect connectors. Remove control switch. If necessary to remove bulbs, turn bulb counterclockwise using a screwdriver and pull out. Remove screws attaching lens to A/C ECU. To install, reverse removal procedure.

Removal & Installation (W/ Navigation System)

1. Using a molding remover, remove 8 center cluster retaining clips, starting with 2 side clips, 3 upper clips and then 3 lower clips. Using a small, flat-blade screwdriver with tip taped, remove all control panel buttons and knobs.
2. Remove 5 rear cover screws and rear A/C amplifier cover. Using a screwdriver, remove differential lock and hazard switch buttons from control panel. Remove screw from rear and remove differential lock and hazard switch. If necessary to remove bulbs, turn bulb counterclockwise using a screwdriver and pull out. To install, reverse removal procedure.

Pressure sensor is located on liquid line, near condenser. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Use 2 wrenches to hold liquid line and to remove pressure sensor. To install, reverse removal procedure. Tighten pressure switch to specification. See TORQUE SPECIFICATIONS . Use a new "O" ring lubricated with refrigerant oil. Evacuate, charge, and leak test A/C system.

Remove lower No. 1 panel. (Scheme 28)and (Scheme 29). Disconnect air outlet servomotor connector. Remove 3 mounting screws and remove servomotor. To install, reverse removal procedure.

Sensor is located on upper condenser support. Remove sensor from support. Disconnect sensor connector. To install, reverse removal procedure.

1. Start engine and allow to idle. If possible, operate A/C system for 10 minutes. Turn engine off. Disconnect negative battery cable, and wait at least 90 seconds. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Raise and support vehicle.
2. Remove engine undercover (splash) shield, and accessory drive belt. Disconnect compressor clutch electrical connector. Disconnect compressor hoses, and cap hose ends to keep moisture out of system. Remove left side axle shaft. Remove compressor mounting bolts. Remove compressor.
3. To install, reverse removal procedure. Tighten mounting bolts and compressor hoses to specified torque. See «TORQUE SPECIFICATIONS»(ref-98895-S06683141862001060500000) . Evacuate, charge, and leak test A/C system.

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove hood lock brace and center brace. Remove automatic transmission cooler. Remove bolts retaining condenser fan and disconnect connector. Remove condenser fan. Remove engine undercover (splash) shield.
2. Disconnect A/C lines from condenser and discard "O" rings. Plug all openings. Remove 4 upper bolts and 2 mounting brackets. Raise condenser slightly and remove 4 lower bolts and 2 lower mounting brackets. Remove 2 center bolts and 2 mounting brackets. Remove condenser.
3. To install, reverse removal procedure. Install new "O" rings lubricated with refrigerant oil. Tighten condenser lines to specification. See «TORQUE SPECIFICATIONS»(ref-98895-S06683141862001060500000) . If installing a new condenser, add 1.4-1.7 ounces of refrigerant oil to condenser. Evacuate, charge, and leak test A/C system.

Locate sensor on radiator center core support, next to fan. Disconnect sensor connector. Remove sensor from support. To install, reverse removal procedure.

Remove evaporator in order to remove expansion valve. To remove front expansion valve, see FRONT EVAPORATOR ASSEMBLY . To remove rear expansion valve, see REAR COOLING UNIT .

Remove evaporator assembly. See FRONT EVAPORATOR ASSEMBLY. Disconnect electrical connectors. Remove bolts/nuts attaching blower unit to vehicle. Remove air inlet servomotor. Disconnect blower motor control relay. Unplug blower motor connector. Remove screws and blower motor. (Scheme 26) To install, reverse removal procedure.

Scheme 26

Removal

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect evaporator refrigerant lines from engine compartment. Plug all openings. Remove instrument panel. See «INSTRUMENT PANEL»(ref-98895-S15316322352001060500000).
2. Remove antenna relay from evaporator cover. (Scheme 27) Disconnect electrical connectors and connector clamp. Remove screws/nuts retaining evaporator assembly to vehicle. Remove front evaporator assembly.
3. Remove 8 screws attaching evaporator cover. Remove evaporator. Carefully remove evaporator temperature sensor. Remove bolts securing expansion valve to evaporator. Discard "O" rings. Plug all openings.

Installation

To install, reverse removal procedure. Install new "O" rings lubricated with refrigerant oil. Tighten expansion valve to specifications. See TORQUE SPECIFICATIONS . If installing a new evaporator, add 1.4 ounces of refrigerant oil to evaporator. Evacuate, charge, and leak test A/C system.

Scheme 27

1. Remove evaporator assembly. See «FRONT EVAPORATOR ASSEMBLY»(ref-98895-S40758035432001060500000). Drain engine coolant until level is lower than heater core. Disconnect heater hoses from heater core. Remove heater core pipe grommets. Disconnect electrical connectors. Remove screws and lower defrost nozzle.
2. Remove nuts and heater unit from vehicle. Remove screws, pipe clamps and bracket. (Scheme 28) Remove heater core. Disconnect air mix servomotor control link, and remove air mix servomotor. Remove air outlet servomotor, aspirator and foot air duct. To install, reverse removal procedure.

Scheme 28

Removal & Installation (Front)

Remove lower No. 1 panel from below steering column. (Scheme 29) Disconnect electrical connector and aspirator hose. Remove screw and sensor from panel. To install, reverse removal procedure.

Removal & Installation (Rear)

Locate sensor in headliner, above rear passenger seat, next to outlet. Use small, flat-blade screwdriver and gently pry sensor from headliner. see scheme 1 Disconnect electrical connector and remove sensor. To install, reverse removal procedure.

1. Disable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING. Remove door sill plates, kick panels and front door opening trims. Using a flat-blade screwdriver with tip taped, remove assist grips and remove front pillar moldings. (Scheme 29)
2. Set front wheels in a straight-ahead position. Remove steering column covers. Remove driver's side air bag. Remove steering wheel center nut. Place match marks on steering wheel and shaft, and remove steering wheel. Remove instrument cluster finish panel and instrument cluster.
3. Remove hood lock release lever and fuel lid release lever. Remove lower No. 1 panel and disconnect connectors. Remove left lower panel and column cover. Remove combination switch from steering column. Remove No. 2 air duct.
4. Place match marks on No. 2 intermediate shaft and control valve shaft. Remove lower steering column No. 2 intermediate shaft. Remove hole cover. Disconnect all connectors and harnesses and remove steering column assembly.
5. Remove instrument cluster. Remove glove box door. Remove undercover behind glove box door. Disconnect passenger's air bag connector from undercover. Remove No. 2 lower panel.
6. Using a molding remover, remove 8 center cluster retaining clips, starting with 2 side clips, 3 upper clips and then 3 lower clips. Using a small, flat-blade screwdriver with tip taped, remove all control panel buttons and knobs. Remove radio or radio and A/C control assembly (if equipped with navigation system).
7. Remove rear console panel, rear console end panel, and rear console box. Remove lower center finish panel. see scheme 33 Remove front console box from under center of instrument panel.
8. Loosen connector bolts and disconnect junction connectors. Remove instrument panel bolts/nuts and remove instrument panel. Remove Engine Control Module (ECM). Remove remaining air ducts. Remove instrument panel braces and reinforcement. To install, reverse removal procedure.

Scheme 29

Remove right rear door sill plate. Remove rear floor mat support plate. Remove right rear quarter panel trim. Disconnect connectors and remove rear A/C amplifier. (Scheme 30)and (Scheme 31). To install, reverse removal procedure.

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect and plug evaporator refrigerant lines from under vehicle. Remove and discard "O" rings.
2. Remove right rear door sill plate. Remove rear floor mat support plate. Remove upper rear center trim. Remove rear seat belt assemblies. Remove right rear quarter panel trim. Remove headlining set clips. Remove clips retaining air duct to right of vehicle.
3. Disconnect rear cooling unit connectors and remove cooling unit. (Scheme 30) Remove A/C amplifier and power transistor. Remove wiring harness and separate cooling unit blower case. Remove blower motor.
4. Disconnect connector clamps and separate cooling unit case halves. Remove rear evaporator temperature sensor. Remove clamps and evaporator tube assembly. Remove evaporator. Remove bolts securing expansion valve to evaporator. Discard "O" rings. (Scheme 31) Plug all openings.

To install, reverse removal procedure. Install new "O" rings lubricated with refrigerant oil. Tighten expansion valve to specified torque. See TORQUE SPECIFICATIONS . If installing a new evaporator, add 1.4 ounces of refrigerant oil to evaporator. Evacuate, charge, and leak test A/C system.

Scheme 30

Scheme 31

1. Remove front seats. Remove rear console box. Remove front console box cover and lower center cluster finish panel. Remove front door sill plates and kick panels. see scheme 33
2. Remove center pillar moldings. Slide floor carpet backward. Disconnect connector and remove rear inlet air temperature sensor from blower motor cover. see scheme 34 To install, reverse removal procedure.

Removal & Installation (Rear Cooler Blower Motor)

Remove right rear door sill plate. (Scheme 30) Remove rear floor mat support plate. Remove lower right quarter panel trim. Remove power transistor. (Scheme 31) To install, reverse removal procedure.

Removal & Installation (Rear Heater Blower Motor)

1. Remove front seats. Remove rear console box. Remove front console box cover and lower center cluster finish panel. Remove front door sill plates and kick panels. see scheme 33
2. Remove center pillar moldings. Slide floor carpet backward. Disconnect 4-pin connector and remove power transistor. see scheme 34 To install, reverse removal procedure.

Locate sensor on driver's side of instrument panel defroster outlet. Using a flat-blade screwdriver, gently pry sensor from instrument panel. Disconnect electrical connector and remove sensor. To install, reverse removal procedure.