Lexus Car ES, IS, LS 1998-06

Removal & Installation

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ES 300



  1. Disconnect the negative battery cable. Wait 90 seconds before doing any further work while the airbag system de-energizes.
  2.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  5. Remove or disconnect the following:

    2 hood release lever screws and the lever
     
    No. 1 lower panel-to-instrument panel bolt/screw, disconnect the electrical connectors and remove the No. 1 lower panel
     
    Lower left hand panel
     
    3 heater protector clips and remove the heater protector
     
    2 screws and the 2 clamps holding the heater core in place
     
    Heater core hoses and discard the O-rings
     
    Pull out heater core from the heater housing

    Click image to see an enlarged view

    Fig. Exploded view of the instrument assembly-ES 300



    Click image to see an enlarged view

    Fig. Exploded view of the heater core, heater/air conditioning housing and related components-ES 300

     

  6.  

To install:

  1. Install or connect the following:

    Heater core to the heater housing
     
    Heater core hoses using new O-rings
     
    2 clamps and the 2 screws holding the heater core in place
     
    Heater protector and connect the 3 heater protector clips
     
    Lower left hand panel No. 1 lower panel, connect the electrical connectors and install the No. 1 lower panel-to-instrument panel bolt/screw
     
    Hood release lever and the 2 lever screws
     

  2.  
  3. Refill the cooling system.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  8.  

Es 330




NOTE
Removal of the heater core requires removal of the entire heater air conditioning assembly.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  5. Set CD changer to ship mode setting using following procedure
    NOTE
    When mode setting is complete -Ship- appears on the display



    Remove all CDs
     
    Simultaneously press -Seek Up- and -Disc- while turning the ignition switch to -Acc-
     

  6.  
  7. Disconnect the negative battery cable. Wait 90 seconds before doing any further work while the airbag system de-energizes.
  8.  
  9. Discharge and recover the air conditioning system refrigerant.
  10.  
  11. Disconnect A/C suction hose (No. 1) and Liquid pipe (A)
    1. Install SST to piping clamp
    2.  
    3. Push down SST and release the clamp lock
      WARNING
      Be careful not to deform the tube, when pushing the SST


      NOTE
      Cap the open fittings immediately to prevent system contamination



      Click image to see an enlarged view

      Fig. Using SST tool-ES 330

    4.  

  12.  
  13. Disconnect the heater core hoses
  14.  
  15. Remove the instrument panel assembly.

    Click image to see an enlarged view

    Fig. Exploded view Air conditioning sub-assembly-ES 330



    Click image to see an enlarged view

    Fig. Exploded view of the heater case assembly-ES330

  16.  

To install:

  1. Install or connect the following:
    NOTE
    Lubricate O-rings with compressor oil



    Heater core unit sub assembly
     
    Heater core into A/C assembly
     
    Screw and clamp
     
    Air conditioning radiator assembly
     
    Heater blower assembly
     
    Instrument panel assembly.
     
    Heater core hoses
     
    A/C suction and pressure hoses, attach with bolt and plate
     



    Negative battery cable
     
    Fill cooling system with coolant
     
    Evacuate and recharge A/C system
     
    Warm up engine and inspect for coolant leaks
     

  2.  

Grand Cherokee



1999-04 Models
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Disconnect and remove the negative battery.
    CAUTION
    After disconnecting the negative battery cable, wait 2 minutes for the driver-s/passenger-s air bag system capacitor to discharge before attempting to do any work around the steering column or instrument.

  4.  
  5. Drain the cooling system into a clean container for reuse.
  6.  
  7. Remove the instrument panel by performing the following procedure:
    1. Turn the steering wheel in the straight-ahead position.
    2.  
    3. Remove the A-pillar trim from both sides of the vehicle.
    4.  
    5. Remove the top cover from the instrument panel.
    6.  
    7. Near the windshield line, remove the 4 instrument panel-to-chassis nuts.
    8.  
    9. Remove the scuff plates from both front door sills.
    10.  
    11. Remove the trim panels from both sides of the inner cowl.
    12.  
    13. Remove the floor console.
    14.  
    15. Remove the fuse cover from the junction box.
    16.  
    17. Remove the instrument panel cluster bezel.
    18.  
    19. Remove the steering column opening cover from the instrument panel.
    20.  
    21. Remove the steering column bracket from the instrument panel column support bracket.
    22.  
    23. Remove the lower steering column shroud cover-to-multifunction switch screw; then, unsnap both halves of the shroud cover from the steering column.
    24.  
    25. Disconnect the instrument panel wiring harness connectors from the following steering column components:

      Both lower clock spring connector receptacles
       
      Left multifunction switch receptacle
       
      Right multifunction switch receptacle
       
      Both ignition switch receptacles
       
      Shifter interlock solenoid receptacle
       
      Sentry Key Immobilizer Module (SKIM) receptacle, if equipped
       

    26.  
    27. Turn the ignition switch to ON position; then, release and remove the shifter interlock cable connector from the ignition lock housing receptacle.
    28.  
    29. Turn the ignition switch to OFF position; this will prevent the steering wheel from turning and the loss of the clock spring centering following steering column removal.
    30.  
    31. Remove the 4 steering column-to-instrument panel steering column bracket nuts.
    32.  
    33. Remove the steering column from the instrument panel.
    34.  
    35. Disconnect both side body wiring harness bulkhead connectors, the Ignition Off Draw (IOD) wiring harness connector and the fused wiring harness connector from the junction block connector receptacles.
    36.  
    37. Disconnect the instrument panel wiring harness-to-floor console component connectors:

      Air bag control module connector receptacle
       
      Parking brake switch terminal
       
      Transmission shifter connector receptacle
       

    38.  
    39. Remove the 2 instrument panel wiring harness-to-floor console ground terminals located behind the air bag control module.
    40.  
    41. Disconnect the instrument panel wiring harness-to-floor console retainers.
    42.  
    43. Remove the instrument panel-to-floor console bracket screws and the bracket.
    44.  
    45. Remove the driver-s side floor duct-to-heater/air conditioning housing assembly screw and remove the duct.
    46.  
    47. If equipped with a manual heating-air conditioning system, disconnect the vacuum harness connector from behind the driver-s side floor duct.
    48.  
    49. Remove the instrument panel steering column support bracket-to-driver-s side of the heater/air conditioning housing assembly screw
    50.  
    51. Remove the instrument panel steering column support bracket-to-intermediate bracket screw.
    52.  
    53. Remove the instrument panel steering column support bracket-to-driver-s side cowl plenum panel nut.
    54.  
    55. Remove the 2 instrument panel-to-driver-s side cowl side inner panel screws.
    56.  
    57. Remove the instrument panel end cap.
    58.  
    59. Remove the lower right center bezel from the instrument panel.
    60.  
    61. At the passenger-s side cowl side inner panel, disconnect the instrument panel wiring harness bulkhead connector from the lower cavity of the inline connector.
    62.  
    63. Near the right side cowl inner panel, located under the end of the instrument panel, disconnect both halves of the radio antenna coaxial cable connector.
    64.  
    65. Disconnect the 2 instrument panel-to-heater/air conditioning assembly wiring harness connectors.
    66.  
    67. At the passenger-s side, remove the 2 instrument panel structural duct-to-heater/air conditioning housing assembly screws.
    68.  
    69. At the passenger-s side cowl side inner panel, remove the 2 instrument panel-to-passenger-s side cowl side inner panel screws.
    70.  
    71. With the help of an assistant, lift the instrument panel from the vehicle.
    72.  

  8.  
  9. Discharge and recover the air conditioning system refrigerant.
  10.  
  11. Disconnect the air conditioning system lines at the evaporator. Plug the openings to prevent contamination.
  12.  
  13. Disconnect the heater hoses from the heater core. Plug the openings to prevent coolant loss.
  14.  
  15. If equipped with a manual temperature control system, unplug the heater/air conditioning system vacuum supply line connector from the T-fitting located near the heater core tubes.
  16.  
  17. From the passenger-s side inner fender shield, remove the coolant reservoir/overflow bottle.
  18.  
  19. From the passenger-s side in the engine compartment dash panel, remove the PCM; DO NOT unplug it, just move it aside.
  20.  
  21. In the engine compartment, remove the heater/air conditioning housing-to-chassis nuts.
  22.  
  23. At the center of the dashboard, remove the rear floor ducts from the floor heat duct outlets.
  24.  
  25. Disconnect the heater/air conditioning housing wire harness connectors.
  26.  
  27. In the passenger compartment, remove the heater/air conditioning housing-to-chassis nuts.
  28.  
  29. Place covers inside the vehicle to catch any spilt coolant.
  30.  
  31. Remove the heater/air conditioning housing assembly from the vehicle.
  32.  
  33. Remove the foam gasket from around the heater core tubes.
    NOTE
    Note the position of the irregular shaped gasket so that it may be reinstalled in its correct position.

  34.  
  35. Remove the heater core retainers and screws.
  36.  
  37. If necessary, remove the mode door actuator for clearance to remove the core.
  38.  
  39. Remove the heater core from the heater/air conditioning housing assembly.

    Click image to see an enlarged view

    Fig. View of the steering column mounting nuts-Grand Cherokee



    Click image to see an enlarged view

    Fig. View of the instrument panel assembly-Grand Cherokee



    Click image to see an enlarged view

    Fig. View of the heater/air conditioning housing assembly-Grand Cherokee



    Click image to see an enlarged view

    Fig. View of the heater core, the heater/air conditioning housing and related components-Grand Cherokee



    Click image to see an enlarged view

    Fig. View of the heater core screws, gasket and retainers-Grand Cherokee

  40.  

To install:

  1. Install the heater core tom the heater/air conditioning housing assembly.
  2.  
  3. If removed, install the mode door actuator.
  4.  
  5. Install the heater core retainers and screws.
  6.  
  7. Install the foam gasket around the heater core tubes.
  8.  
  9. Install the heater/air conditioning housing assembly to the vehicle.
  10.  
  11. In the passenger compartment, install the heater/air conditioning housing-to-chassis nuts.
  12.  
  13. Connect the heater/air conditioning housing wire harness connectors.
  14.  
  15. At the center of the dashboard, install the rear floor ducts to the floor heat duct outlets.
  16.  
  17. In the engine compartment, install the heater/air conditioning housing-to-chassis nuts.
  18.  
  19. At the passenger-s side in the engine compartment dash panel, install the PCM.
  20.  
  21. At the passenger-s side inner fender shield, install the coolant reservoir/overflow bottle.
  22.  
  23. If equipped with a manual temperature control system, plug the heater/air conditioning system vacuum supply line connector to the T-fitting located near the heater core tubes.
  24.  
  25. Connect the heater hoses to the heater core.
  26.  
  27. Connect the air conditioning system lines to the evaporator.
  28.  
  29. Evacuate and charge the air conditioning system refrigerant.
  30.  
  31. Remove the instrument panel by performing the following procedure:
    1. Turn the steering wheel in the straight-ahead position.
    2.  
    3. Install the A-pillar trim to both sides of the vehicle.
    4.  
    5. Install the top cover to the instrument panel.
    6.  
    7. Near the windshield line, install the 4 instrument panel-to-chassis nuts.
    8.  
    9. Install the scuff plates to both front door sills.
    10.  
    11. Install the trim panels to both sides of the inner cowl.
    12.  
    13. Install the floor console.
    14.  
    15. Install the fuse cover to the junction box.
    16.  
    17. Install the instrument panel cluster bezel.
    18.  
    19. Install the steering column opening cover to the instrument panel.
    20.  
    21. Install the steering column bracket to the instrument panel column support bracket.
    22.  
    23. Install the lower steering column shroud cover-to-multifunction switch screw; then, snap both halves of the shroud cover to the steering column.
    24.  
    25. Connect the instrument panel wiring harness connectors to the following steering column components:

      Sentry Key Immobilizer Module (SKIM) receptacle, if equipped
       
      Shifter interlock solenoid receptacle
       
      Both ignition switch receptacles
       
      Right multifunction switch receptacle
       
      Left multifunction switch receptacle
       
      Both lower clock spring connector receptacles
       

    26.  
    27. Turn the ignition switch to ON position; then, release and install the shifter interlock cable connector to the ignition lock housing receptacle.
    28.  
    29. Install the 4 steering column-to-instrument panel steering column bracket nuts.
    30.  
    31. Install the steering column to the instrument panel.
    32.  
    33. Connect both side body wiring harness bulkhead connectors, the Ignition Off Draw (IOD) wiring harness connector and the fused wiring harness connector to the junction block connector receptacles.
    34.  
    35. Disconnect the instrument panel wiring harness-to-floor console component connectors:

      Transmission shifter connector receptacle
       
      Parking brake switch terminal
       
      Air bag control module connector receptacle
       

    36.  
    37. Install the 2 instrument panel wiring harness-to-floor console ground terminals located behind the air bag control module.
    38.  
    39. Connect the instrument panel wiring harness-to-floor console retainers.
    40.  
    41. Install the instrument panel-to-floor console bracket and the screws.
    42.  
    43. Install the driver-s side floor duct and the duct-to-heater/air conditioning housing assembly screw.
    44.  
    45. If equipped with a manual heating-air conditioning system, connect the vacuum harness connector behind the driver-s side floor duct.
    46.  
    47. Install the instrument panel steering column support bracket-to-driver-s side of the heater/air conditioning housing assembly screw.
    48.  
    49. Install the instrument panel steering column support bracket-to-intermediate bracket screw.
    50.  
    51. Install the instrument panel steering column support bracket-to-driver-s side cowl plenum panel nut.
    52.  
    53. Install the 2 instrument panel-to-driver-s side cowl side inner panel screws.
    54.  
    55. Install the instrument panel end cap.
    56.  
    57. Install the lower right center bezel to the instrument panel.
    58.  
    59. At the passenger-s side cowl side inner panel, connect the instrument panel wiring harness bulkhead connector to the lower cavity of the inline connector.
    60.  
    61. Near the right cowl side inner panel located under the end of the instrument panel, connect both halves of the radio antenna coaxial cable connector.
    62.  
    63. Connect the 2 instrument panel-to-heater/air conditioning assembly wiring harness connectors.
    64.  
    65. At the passenger-s side, install the 2 instrument panel structural duct-to-heater/air conditioning housing assembly screws.
    66.  
    67. At the passenger-s side cowl side inner panel, install the 2 instrument panel-to-passenger-s side cowl side inner panel screws.
    68.  
    69. With the help of an assistant, lift the instrument panel into the vehicle.
    70.  

  32.  
  33. Refill the cooling system.
  34.  
  35. Connect the negative battery.
  36.  
  37. Run the engine to normal operating temperatures. Check the climate control operation and check for leaks.
  38.  

Is 250 And Is 350



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Discharge the A/C system.
  4.  
  5. Disconnect the negative battery cable. Wait 90 seconds before doing any further work while the airbag system de-energizes.
  6.  
  7. Drain the cooling system into a clean container for reuse.
  8.  
  9. Align the front wheels facing straight ahead.
  10.  
  11. Remove or disconnect the following:

    Cool air intake duct seal
     
    Left and right engine room side covers
     

  12.  
  13. Remove the left and right front upper fender protector as follows:
    1. Using a clip remover, separate the clip on the rubber portion of the cowl top ventilator louver subassembly from the front upper fender protector.
    2.  
    3. Disengage the 3 clips and the claw to remove the front upper fender protector.
    4.  

  14.  
  15. Remove the left and right roof drip side finish moulding as follows:
    1. Put protective tape around the roof drip side finish moulding.
    2.  
    3. Using a moulding remover, disengage the 6 clips and remove the roof drip side finish moulding.
      NOTE
      Do not remove the clips. If the clips are damaged or fall off, replace them with new clips.

    4.  

  16.  
  17. Remove the windshield wiper motor assembly.
  18.  
  19. Separate suction pipe sub-assembly as follows:
    1. Remove the bolt, and slide the hook connector.
    2.  
    3. Disconnect the suction pipe sub-assembly.
    4.  
    5. Remove the O-ring from the suction pipe subassembly.
      WARNING
      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

    6.  

  20.  
  21. Separate liquid tube sub-assembly as follows:
    1. Disconnect the liquid tube sub-assembly.
    2.  
    3. Remove the O-ring from the liquid tube subassembly.
    4.  

  22.  
  23. Disconnect the inlet and outlet heater water outlet hoses
  24.  
  25. Remove the instrument panel assembly.
  26.  
  27. Remove or disconnect the following:

    2 screws, 3 bolts, and air conditioner unit assembly
     
    Mounting screw and No. 2 air duct
     
    Connector, mounting screw and air conditioning amplifier assembly
     

  28.  
  29. Remove the heater core from the A/C-blower assembly unit as follows:


    1. Disconnect the wiring connector, remove the 3 screws and air outlet control servo motor.
    2.  
    3. Disengage 4 clamps, connector and wire harness to air mix control servo motor.
    4.  
    5. Remove the 3 screws and heater piping cover.
    6.  
    7. Remove the 3 screws and air mix control servo motor.
    8.  
    9. Remove the heater radiator unit sub-assembly (heater core)

      Click image to see an enlarged view

      Fig. Exploded view of the A/C unit assembly, instrument panel reinforcement and related components-IS 250, IS 350, GS 300 (2006) and GS 430 (2006)



      Click image to see an enlarged view

      Fig. Exploded view of the heater radiator unit (heater core), heater housing and related components-IS 250, IS 350, GS 300 (2006) and GS 430 (2006)

    10.  

  30.  

To install:

  1. Install or connect the following:

    Heater core to the A/C blower housing
     
    Air conditioning amplifier assembly
     
    No. 2 air duct
     
    A/C blower unit assembly. Torque the 3 bolts and 2 screws to 7 ft. lbs. (10 Nm).
     
    Instrument panel assembly
     
    Inlet and outlet heater water outlet hoses
     
    Liquid tube sub-assembly
     
    Suction pipe sub-assembly
     
    Windshield wiper motor and link assembly
     
    Left and right roof drip side finish mouldings
     
    Left and right front upper fender protectors
     
    Left and right engine room side covers
     
    Cool air intake duct seal
     

  2.  
  3. Refill the cooling system.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. Evacuate, charge and leak test the air conditioning system refrigerant.
  8.  
  9. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  10.  

Is 300 And Es 300



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable. Wait 90 seconds before doing any further work while the airbag system de-energizes.
  4.  
  5. Drain the cooling system into a clean container for reuse.
  6.  
  7. Remove or disconnect the following:

    2 hood release lever screws and the lever
     
    No. 1 lower panel-to-instrument panel bolt/screw, disconnect the electrical connectors and remove the No. 1 lower panel
     
    Lower left hand panel
     
    3 heater protector clips and remove the heater protector
     
    2 screws and the 2 clamps holding the heater core in place
     
    Heater core hoses and discard the O-rings
     
    Pull out heater core from the heater housing

    Click image to see an enlarged view

    Fig. Exploded view of the instrument assembly-ES 300



    Click image to see an enlarged view

    Fig. Exploded view of the heater core, heater/air conditioning housing and related components-ES 300

     

  8.  

To install:

  1. Install or connect the following:

    Heater core to the heater housing
     
    Heater core hoses using new O-rings
     
    2 clamps and the 2 screws holding the heater core in place
     
    Heater protector and connect the 3 heater protector clips
     
    Lower left hand panel
     
    No. 1 lower panel, connect the electrical connectors and install the No. 1 lower panel-to-instrument panel bolt/screw
     
    Hood release lever and the 2 lever screws
     

  2.  
  3. Refill the cooling system.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  8.  

LS 400



  1. Disconnect the negative battery cable. Wait 90 seconds before doing any further work while the airbag system de-energizes.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system into a clean container for reuse.
  6.  
  7. Remove or disconnect the following:

    Undercover and the No. 1 safety pad-to-instrument panel screws and the panel at the driver-s side
     
    No. 2 heater-to-register duct
     
    Heater core-to-heater housing screw and clamp
     
    Heater hoses from the heater core
     
    Heater core from the heater housing
     
    Discard the O-rings

    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel-LS 400



    Click image to see an enlarged view

    Fig. Exploded view of the heater core, heater/air conditioning housing and related components-LS 400

     

  8.  

To install:

  1. Install or connect the following:

    New O-rings to the heater core
     
    Heater core to the heater housing
     
    Heater hoses to the heater core
     
    Heater core clamp and the heater core-to-heater housing screw
     
    No. 2 heater-to-register duct
     
    Undercover and the No. 1 safety pad-to-instrument panel and the panel screws at the driver-s side
     

  2.  
  3. Refill the cooling system.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable. Wait 90 seconds before doing any further work while the airbag system de-energizes.
  4.  
  5. Drain the engine coolant from the radiator. It is not necessary to drain out all coolant.
  6.  
  7. Remove the No.1 (left side) safety pad.
  8.  
  9. Remove the No.1 (left side) under cover.
  10.  
  11. Remove the No.2 heater to register duct (left side).

    Click image to see an enlarged view

    Fig. Heater core (heater radiator) position in the air conditioning unit.-LS 400

  12.  
  13. Remove the heater core (heater radiator) as follows:


    1. Remove the screw and clamp.
    2.  
    3. Remove the 2 screws, 2 clamps and disconnect the heater radiator pipes.
    4.  
    5. Pull out the heater radiator from the air conditioning unit.
    6.  
    7. Remove and discard the 2 O-rings.
    8.  

  14.  

To install:

  1. Install the heater core (heater radiator) as follows:


    1. Install 2 new O-rings.
    2.  
    3. Insert the heater radiator into the air conditioning unit.
    4.  
    5. Connect the heater radiator pipes.
    6.  
    7. Install the screws and clamps.
    8.  

  2.  
  3. Install the No.2 heater to register duct (left side).
  4.  
  5. Install the No.1 (left side) under cover.
  6.  
  7. Install the No.1 (left side) safety pad.
  8.  
  9. Refill the cooling system.
  10.  
  11. Connect the negative battery cable.
  12.  

LS 430



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable. Wait 90 seconds before doing any further work while the airbag system de-energizes.
  4.  
  5. Drain the cooling system into a clean container for reuse.
  6.  
  7. Remove or disconnect the following:

    Undercover and the No. 1 safety pad-to-instrument panel screws and the panel at the driver-s side
     
    No. 2 heater-to-register duct
     
    Heater core-to-heater housing screw and clamp
     
    Heater hoses from the heater core
     
    Heater core from the heater housing
     
    Discard the O-rings
     

  8.  

To install:

  1. Install or connect the following:

    New O-rings to the heater core
     
    Heater core to the heater housing
     
    Heater hoses to the heater core
     
    Heater core clamp and the heater core-to-heater housing screw
     
    No. 2 heater-to-register duct
     
    Undercover and the No. 1 safety pad-to-instrument panel and the panel screws at the driver-s side
     

  2.  
  3. Refill the cooling system.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  8.  

 
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