Automatic A/c-Heater Systems: Removal & Installation Lexus RX I

REMOVAL & INSTALLATION

Remove passenger side lower finish panel. Remove air filter cover. Remove air filter and frame. Remove air filter from frame. To install, reverse removal procedure.

1. Remove lower center cluster (center console) finish panel. (Scheme 22) Remove 4 bolts and center cluster finish panel (integration control panel). Remove 3 screws and display panel. Remove 4 screws and radio.
2. Remove 6 screws and panel ECU. Remove 15 screws and A/C-heater control panel. Remove knobs and plate from control panel. To install, reverse removal procedure.

1. If possible, operate engine at idle with A/C on for about 10 minutes. Stop engine and disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove A/C compressor drive belt.
2. Disconnect refrigerant lines at A/C compressor. Disconnect wiring harness and remove generator. Remove drive belt adjusting bar bracket. Remove 3 bolts and A/C compressor. To install, reverse removal procedure. See «TORQUE SPECIFICATIONS»(ref-98896-S21837706252001060500000) .

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Drain radiator until coolant level is lower than heater core coolant hoses. (Scheme 19) Remove wiper arm, cowl top ventilator louvers and wiper motor assembly. Remove hood.
2. Remove outer front cowl top panel assembly. Remove instrument panel and reinforcement. See «INSTRUMENT PANEL»(ref-98896-S14893859072001060500000). Disconnect refrigerant lines and heater hoses from engine compartment side. Discard "O" rings. Cap open fittings to protect system from moisture and debris.
3. Remove blower unit. See «BLOWER UNIT»(ref-98896-S25390350972001060500000). Release 2 clamps and remove lower defroster nozzle and heater-to-register center duct. Remove No. 1 console box duct. Disconnect connector. Remove 2 nuts, 2 bolts and A/C unit.
4. To install, reverse removal procedures. Lubricate "O" rings with clean refrigerant oil. Ensure clamps are 0.04-0.28" (1.0-7.0 mm) from end of hose and positioned correctly. Tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-98896-S21837706252001060500000).

Scheme 19

Remove blower unit. See BLOWER UNIT. Remove 3 screws and remove air inlet control servomotor. (Scheme 19)and (Scheme 20). To install, reverse removal procedure.

Scheme 20

1. Disable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING. Remove right side cowl trim. Remove right front door scuff plate. Remove passenger side undercover. (Scheme 22)
2. Open glove box door. Pry out air bag connect cover plate (inside glove box). Disconnect air bag connector. Remove passenger side lower panel. Remove CD changer (if equipped). Remove 2 bolts, 2 nuts, and passenger's air bag assembly.
3. Remove 3 screws and air duct. Disconnect blower unit wiring harness and detach wiring harness clamps. Remove 2 nuts, 2 bolts, one screw and blower unit. (Scheme 19) To install, reverse removal procedure.

Remove passenger side undercover. Disconnect wiring harness at blower motor. Remove 3 screws and blower motor. (Scheme 20) To install, reverse removal procedure.

1. Discharge A/C system, using refrigerant recovery/recycling equipment. Remove 7 clips and radiator upper seal. Remove front bumper. Disconnect refrigerant lines from right side of condenser. Remove condenser from vehicle.
2. To install, reverse removal procedure. See «TORQUE SPECIFICATIONS»(ref-98896-S21837706252001060500000) . If installing a new condenser, add 1.4 ounces of refrigerant oil to condenser. Lubricate "O" rings with clean refrigerant oil.

1. Remove A/C unit. See «A/C UNIT»(ref-98896-S07227637182001071400000). Remove air outlet servomotor. Remove wiring harness and bracket. (Scheme 19)and (Scheme 21).
2. Remove 2 screws, 2 plates and remove heater core. Remove blower motor control relay. Remove air mix servomotor. Disconnect evaporator temperature sensor connector clamp, and remove evaporator temperature sensor and bracket.
3. Remove expansion valve. See «EXPANSION VALVE»(ref-98896-S14981741822001060500000). Remove driver side air duct. Using a 5-mm Allen wrench, remove 2 bolts and expansion valve tubing. Cap open fittings. Discard "O" rings.
4. Remove 7 screws and evaporator cover. Pull out evaporator unit. To install, reverse removal procedure. If installing a new evaporator, add 1.4 ounces of refrigerant oil to evaporator. Lubricate "O" rings with clean refrigerant oil.

Scheme 21

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove instrument panel. See «INSTRUMENT PANEL»(ref-98896-S14893859072001060500000). Remove packing around expansion valve. (Scheme 21)
2. Using a 5-mm Allen wrench, remove bolts and expansion valve tubing. Remove expansion valve from tube connector. To install, reverse removal procedure. Lubricate "O" rings with refrigerant oil. See «TORQUE SPECIFICATIONS»(ref-98896-S21837706252001060500000).

Ensure front wheels are in straight-ahead position. Disable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING. Remove upper steering column cover. Remove instrument cluster finish panel. (Scheme 22) Remove instrument cluster. To install, reverse removal procedure.

1. Ensure front wheels are in straight-ahead position. Disable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING. Using a flat-blade screwdriver with tip taped, remove instrument panel side panels. Remove front door scuff plates. (Scheme 22) Remove front door opening trim.
2. Remove "A" pillar garnish molding. Remove cowl side trim. Remove speaker panels from top of instrument panel safety pad. Disconnect wiring harness connectors. Remove passenger side undercover.
3. Open glove box door. Pry out air bag connect cover plate (inside glove box). Disconnect air bag connector. Remove passenger side lower panel. Remove CD changer (if equipped). Remove 2 bolts, 2 nuts, and passenger side air bag assembly.
4. Remove steering wheel lower covers. Loosen driver side air bag Torx screws until groove along screw circumference catches on screw case. Pull out steering wheel pad and disconnect air bag connector. Remove driver side air bag (steering wheel pad).
5. Disconnect steering wheel connector. Remove steering wheel nut. Using puller, remove steering wheel. Remove trim plate surrounding ignition lock cylinder. Remove driver side lower instrument finish panel (disconnect hood opener control cable).
6. Remove driver side lower instrument panel insert. Remove steering column upper and lower covers. Disconnect 3 wiring harness connectors. Disconnect air bag connector. Remove 3 screws and combination switch with spiral cable (clockspring).
7. Loosen hose clamp and disconnect steering column intermediate shaft sub-assembly. Remove steering column universal joint bolts. Remove 4 nuts and steering column assembly.
8. Remove lower center cluster (center console) finish panel. Remove center floor carper covers. Remove lower center finish panel. Remove 4 screws and center cluster finish panel. Remove 2 screws and instrument cluster finish panel. Remove instrument cluster (A/C ECU). Remove 2 bolts and lower retainers.
9. Disconnect shift control link from floor shift assembly. Disconnect wiring harness connectors. Remove 4 nuts and floor shift assembly. Remove air ducts. Remove instrument panel safety pad. Remove left and right center braces.
10. Remove 2 nuts and body control unit. Remove 2 nuts and Anti-Lock Brake System (ABS) control unit. Remove pedal and return spring. Remove instrument panel junction block. Remove 4 nuts, 4 bolts, and instrument panel reinforcement. To install, reverse removal procedure. See «TORQUE SPECIFICATIONS»(ref-98896-S21837706252001060500000).

Scheme 22

Scheme 23