Lexus GS, SC 1998-06

Removal & Installation

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2000-05 GS 300, GS 400 And 2001-05 GS 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. Discharge and recover the air conditioning system refrigerant.
  8.  
  9. Disconnect the refrigerant lines from the evaporator by removing the bolt, sliding the plate, then disconnecting both lines and discard the O-rings. Plug the openings to prevent contamination
  10.  
  11. Remove or disconnect the following:

    Heater hoses from the heater core
     
    No. 1 grommet, the heater pipe grommet and the drain hose grommet
     
    Instrument panel assembly.
     

  12.  
  13. Remove the blower unit by removing or disconnecting the following:

    Connector clamp
     
    3 air duct-to-blower housing screws and the air duct
     
    Electrical connector bracket, the wiring harness clamps and the wiring harness
     
    Blower housing connectors
     
    2 blower housing-to-bracket bolts and the bracket
     
    Blower housing-to-chassis bolt, screw, nut and the blower housing
     

  14.  
  15. Remove or disconnect the following:

    2 center air duct-to-heater/air conditioning housing screws and the air duct
     
    Move the floor carpet rearward
     
    Wiring harness clamps
     
    2 air duct bolts and the ducts at both sides
     

  16.  
  17. Remove the heater/air conditioning housing by removing or disconnecting the following:

    Electrical connector
     
    Wiring harness set nut
     
    Wiring harness clamp
     
    Heater/air conditioning housing 2 nuts and bolt
     
    Heater/air conditioning housing
     

  18.  
  19. Remove the heater core-to-heater/air conditioning housing clamp screw and the clamp.
  20.  
  21. Pull the heater core from the heater/air conditioning housing.

    Click image to see an enlarged view

    Fig. Exploded view of the heater/air conditioning housing and related components-2002-05 GS 300 and GS 430



    Click image to see an enlarged view

    Fig. Exploded view of the heater core, heater housing and related components-2002-05 GS 300 GS 430

  22.  

To install:

  1. Install the heater core to the heater/air conditioning housing.
  2.  
  3. Install the heater core clamp and the clamp-to-heater/air conditioning housing screw.
  4.  
  5. Install the heater/air conditioning housing by installing or connecting the following:

    Heater/air conditioning housing
     
    Heater/air conditioning housing 2 nuts and bolt
     
    Wiring harness clamp
     
    Wiring harness set nut
     
    Electrical connector
     

  6.  
  7. Install or connect the following:

    Air duct and the 2 duct bolts on both sides
     
    Wiring harness clamps
     
    Move the floor carpet forward
     
    Center air duct and the 2 air duct-to-heater/air conditioning housing screws
     

  8.  
  9. Install the blower unit by installing or connecting the following:

    Blower housing and the blower housing-to-chassis bolt, screw and nut
     
    Blower housing and the 2 bracket-to-bracket bolts
     
    Blower housing connectors
     
    Electrical connector bracket, the wiring harness clamps and the wiring harness
     
    Air duct and the 3 air duct-to-blower housing screws
     
    Connector clamp
     
    Instrument panel assembly.
     
    No. 1 grommet, the heater pipe grommet and the drain hose grommet
     
    Heater hoses to the heater core
     
    Refrigerant lines (using new O-rings) and the refrigerant lines-to-evaporator bolt
     

  10.  
  11. Refill the cooling system.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Evacuate, charge and leak test the air conditioning system refrigerant.
  16.  
  17. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  18.  

2006 GS 300 And 2006 GS 430



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Discharge the A/C system.
  4.  
  5. Set radio receiver assembly to shipment mode as follows:
    1. Be sure that all discs and tapes have been removed from the unit.
    2.  
    3. Be sure that the engine switch off.
    4.  
    5. While simultaneously pressing the "SEEK UP" and "DISC" switches, turn the engine switch on (ACC).
      NOTE
      The CD loading door indicator light blinks during mode setting and it remains lit after the setting is completed.

    6.  
    7. Turn the engine switch off.
    8.  

  6.  
  7. Disconnect the negative battery cable. Wait 90 seconds before doing any further work while the airbag system de-energizes.
  8.  
  9. Drain the cooling system into a clean container for reuse.
  10.  
  11. Align the front wheels facing straight ahead.
  12.  
  13. Remove or disconnect the following:

    Cool air intake duct seal
     
    Left and right engine room side covers
     
    Left and right front pillar to front side seals, using a clip remover to detach the 3 claws
     
    Left and right nut, windshield wiper arms and blades
     
    Left and right front fender to cowl side seals by moving the component toward the center of the vehicle to detach the 2 claws
     

  14.  
  15. Remove cowl top ventilator louver assembly as follows:


    1. Remove the 2 clips and detach the 5 claws.
    2.  
    3. Pull the ventilator louver in the direction indicated by the arrow in the illustration to detach the 10 claws and remove the ventilator louver.
    4.  

  16.  
  17. Remove the windshield wiper motor and link assembly as follows:
    1. Disconnect the connector. Then detach the 2 clamps and remove the wire harness from the cowl top panel.
      NOTE
      There are 6 bolts total, however, 2 bolts cannot be removed from the wiper motor and link because they are integrated into the wiper motor and link.

    2.  
    3. Remove the 4 bolts and wiper motor and link.
    4.  

  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 sub-assembly.
      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.

      Inlet and outlet heater water outlet hoses
       
      Instrument panel assembly.
       
      A/C blower unit assembly
       
      Mounting screw and No. 2 air duct
       
      Upper and lower foot ducts
       
      Connector, mounting screw and air conditioning amplifier assembly
       

    4.  

  22.  
  23. Remove the heater core from the A/C-blower assembly unit as follows:


    1. Disconnect the wiring connector, remove the 3 screws and right side air outlet control servo motor.
    2.  
    3. Disengage 3 clamps, connector and wire harness to right side air mix control servo motor.
    4.  
    5. Remove the 2 screws and heater piping cover.
    6.  
    7. Remove the 3 screws and right side air mix control servo motor.
    8.  
    9. Move the A/C wiring harness out of the way of the heater radiator unit.
    10.  
    11. 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)

    12.  

  24.  

To install:

  1. Install or connect the following:

    Heater core to the A/C blower housing
     
    A/C wiring harness back into position
     
    Right side air mix control servo motor
     
    Heater piping cover
     
    Right side air outlet control servo motor
     
    Air conditioning amplifier assembly
     
    Upper and lower foot ducts
     
    No. 2 air duct
     
    A/C blower unit assembly. Torque the retaining nut to 7 ft. lbs. (10 Nm).
     
    Instrument panel assembly.
     
    Inlet and outlet heater water outlet hoses
     

  2.  
  3. Install the liquid tube sub-assembly as follows:
    1. Remove the vinyl tape attached to the tube.
    2.  
    3. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the liquid tube.
    4.  
    5. Install the O-ring on the liquid tube.
    6.  
    7. Install the liquid tube to the fitting hole.
    8.  

  4.  
  5. Install the suction pipe sub-assembly as follows:
    1. Remove the vinyl tape attached to the pipe.
    2.  
    3. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction pipe.
    4.  
    5. Install the O-ring on the suction pipe.
    6.  
    7. Move the hook connector in a counterclockwise direction.
    8.  
    9. Insert the pipe joints into the fitting holes securely and tighten the bolt to 7 ft. lbs. (10 Nm).

      Wiper motor and link assembly
       
      Cowl top ventilator louver assembly
       
      Left and right front fender to cowl side seals
       
      Windshield wiper arms and blades
       
      Left and right front pillar to front side seals
       
      Left and right engine room side covers
       
      Cool air intake duct seal
       

    10.  

  6.  
  7. Perform system initialization procedure.
  8.  
  9. Refill the cooling system.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Evacuate, charge and leak test the air conditioning system refrigerant.
  14.  
  15. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  16.  

GS 300 And GS 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. Discharge and recover the air conditioning system refrigerant.
  8.  
  9. Disconnect the refrigerant lines from the evaporator by removing the bolt, sliding the plate, then disconnecting both lines and discard the O-rings. Plug the openings to prevent contamination
  10.  
  11. Remove or disconnect the following:

    Heater hoses from the heater core
     
    No. 1 grommet, the heater pipe grommet and the drain hose grommet
     

  12.  
  13. Remove the steering wheel by removing or disconnecting the following:

    Place the front wheels in the straight-ahead position.
     
    Torx®bolt covers at both sides of the steering wheel
     
    Loosen the Torx®bolts (using a Torx®wrench), until the circumference ring on the bolt catches on the screw case
     
    Lift the air bag, disconnect the electrical connector and remove it
     
    Steering wheel nut and press the steering wheel from the steering column
     

  14.  
  15. Remove the instrument panel by removing or disconnecting the following:

    Front pillar garnishes and the front door scuff plates
     
    Steering column cover screws and the covers
     
    Electrical connectors and remove the combination switch
     
    End pad
     
    2 No. 1 undercover-to-instrument panel screws and the undercover
     
    2 hood lock release screws and the release
     
    4 No. 1 safety pad-to-instrument panel bolts, screw and the safety pad
     
    Parking brake handle and the No. 1 switch hole base
     
    4 steering column-to-instrument panel nuts, disconnect the spring from the brake pedal and remove the steering column
     
    Instrument cluster finish panel using a suitable prytool
     
    4 instrument cluster-to-instrument panel screws, disconnect the electrical connectors and remove the instrument cluster
     
    No. 2 undercover using a suitable prytool
     
    Plate and disconnect the air bag electrical connector inside the glove box
     
    Glove box-to-instrument panel 2 bolts, 3 screws, and the glove box
     
    3 CD changer-to-instrument panel nuts, disconnect the electrical connectors and remove the CD changer
     
    Ashtray
     
    No. 2 register using a suitable prytool and disconnect the connector
     
    Audio unit-to-instrument panel 2 bolts, 2 screws and the audio unit
     
    Cluster finish panel using a suitable prytool, disconnect the connectors and remove the panel.
     
    Console box carpet
     
    Lower rear console box
     
    Rear console armrest
     
    No. 3 console box mounting bracket
     
    Console box
     
    No. 1 console box duct
     
    No. 7 heater-to-register
     
    5 instrument panel-to-chassis bolts, the nut, the screw and the instrument panel
     
    No. 1 and No. 2 brace
     
    Reinforcement-to-chassis 5 nuts, 4 bolts and the reinforcement
     
    Ventilation nozzles from the heater/air conditioning housing
     

  16.  
  17. Remove the blower unit by removing or disconnecting the following:

    Connector clamp
     
    3 air duct-to-blower housing screws and the air duct
     
    Electrical connector bracket, the wiring harness clamps and the wiring harness
     
    Blower housing connectors
     
    2 blower housing-to-bracket bolts and the bracket
     
    Blower housing-to-chassis bolt, screw, nut and the blower housing
     

  18.  
  19. Remove or disconnect the following:

    2 center air duct-to-heater/air conditioning housing screws and the air duct
     
    Move the floor carpet rearward
     
    Wiring harness clamps
     
    2 air duct bolts and the ducts at both sides
     

  20.  
  21. Remove the heater/air conditioning housing by removing or disconnecting the following:

    Electrical connector
     
    Wiring harness set nut
     
    Wiring harness clamp
     
    Heater/air conditioning housing 2 nuts and bolt
     
    Heater/air conditioning housing
     

  22.  
  23. Remove the heater core-to-heater/air conditioning housing clamp screw and the clamp.
  24.  
  25. Pull the heater core from the heater/air conditioning housing.
  26.  


    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel and related components-GS 300, GS 330 and GS 430



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel, ventilation ducts and related components-GS 300, GS 330 and GS 430



    Click image to see an enlarged view

    Fig. Exploded view of the heater/air conditioning housing and related components-GS 300, GS 330 and GS 430



    Click image to see an enlarged view

    Fig. Exploded view of the heater core, heater housing and related components-GS 300, GS 330 and GS 430


To install:

  1. Install the heater core to the heater/air conditioning housing.
  2.  
  3. Install the heater core clamp and the clamp-to-heater/air conditioning housing screw.
  4.  
  5. Install the heater/air conditioning housing by installing or connecting the following:

    Heater/air conditioning housing
     
    Heater/air conditioning housing 2 nuts and bolt
     
    Wiring harness clamp
     
    Wiring harness set nut
     
    Electrical connector
     

  6.  
  7. Install or connect the following:

    Air duct and the 2 duct bolts on both sides
     
    Wiring harness clamps
     
    Move the floor carpet forward
     
    Center air duct and the 2 air duct-to-heater/air conditioning housing screws
     

  8.  
  9. Install the blower unit by installing or connecting the following:

    Blower housing and the blower housing-to-chassis bolt, screw and nut
     
    Blower housing and the 2 bracket-to-bracket bolts
     
    Blower housing connectors
     
    Electrical connector bracket, the wiring harness clamps and the wiring harness
     
    Air duct and the 3 air duct-to-blower housing screws
     
    Connector clamp
     

  10.  
  11. Install the instrument by installing or connecting the following:

    Ventilation nozzles to the heater/air conditioning housing
     
    Reinforcement and the reinforcement-to-chassis 5 nuts and 4 bolts
     
    No. 1 and No. 2 brace
     
    Instrument panel and the 5 instrument panel-to-chassis bolts, the nut and the screw
     

  12.  
  13. Install or connect the following:

    No. 7 heater-to-register
     
    No. 1 console box duct
     
    Console box
     
    No. 3 console box mounting bracket
     
    Rear console armrest
     
    Lower rear console box
     
    Console box carpet
     
    Connectors and install the cluster finish panel
     
    Audio unit and the audio unit-to-instrument panel 2 bolts and 2 screws
     
    Connector and install the No. 2 register
     
    Ashtray
     
    CD changer, connect the electrical connectors and install the 3 CD changer-to-instrument panel nuts
     
    Glove box and the glove box-to-instrument panel 2 bolts and 3 screws
     
    Air bag electrical connector and install the plate inside the glove box
     
    No. 2 undercover
     
    Instrument cluster, connect the electrical connectors and install the 4 instrument cluster-to-instrument panel screws
     
    Instrument cluster finish panel
     
    Steering column, connect the spring to the brake pedal and install the 4 steering column-to-instrument panel nuts
     
    Parking brake handle and the No. 1 switch hole base
     
    No. 1 safety pad and the 4 safety pad-to-instrument panel bolts and screw
     
    Hood lock release and the 2 release screws
     
    No. 1 undercover and the 2 undercover-to-instrument panel screws
     
    End pad
     
    Combination switch and connect the electrical connectors
     
    Steering column covers and the cover screws
     
    Front pillar garnishes and the front door scuff plates
     

  14.  
  15. Install the steering wheel by installing or connecting the following:

    Steering wheel and torque the steering wheel nut to 26 ft. lbs. (35 Nm)
     
    Electrical connector and install the air bag
     
    Tighten the Torx®bolts to 80 inch lbs. (9.0 Nm) using a Torx®wrench
     
    Torx®bolt covers at both sides of the steering wheel
     
    No. 1 grommet, the heater pipe grommet and the drain hose grommet
     
    Heater hoses to the heater core
     
    Refrigerant lines (using new O-rings) and the refrigerant lines-to-evaporator bolt
     

  16.  
  17. Refill the cooling system.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Evacuate, charge and leak test the air conditioning system refrigerant.
  22.  
  23. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  24.  

GS 300/GS400



1998-00 Models
  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. Discharge and recover the air conditioning system refrigerant.
  6.  
  7. Remove or disconnect the following:

    Refrigerant lines-to-evaporator bolt, slide the plate clockwise, disconnect both lines and discard the O-rings. Plug the openings to prevent contamination
     
    Heater hoses from the heater core
     
    No. 1 grommet, the heater pipe grommet and the drain hose grommet
     

  8.  
  9. Remove the steering wheel by removing or disconnecting the following:

    Place the front wheels in the straight-ahead position.
     
    Torx bolt covers at both sides of the steering wheel
     
    Loosen the Torx bolts (using a Torx wrench), until the circumference ring on the bolt catches on the screw case
     
    Lift the air bag, disconnect the electrical connector and remove it
     
    Steering wheel nut and press the steering wheel from the steering column
     

  10.  
  11. Remove the instrument by removing or disconnecting the following:

    Front pillar garnishes and the front door scuff plates
     
    Steering column cover screws and the covers
     
    Electrical connectors and remove the combination switch
     
    End pad
     
    2 No. 1 undercover-to-instrument panel screws and the undercover
     
    2 hood lock release screws and the release
     
    4 No. 1 safety pad-to-instrument panel bolts, screw and the safety pad
     
    Parking brake handle and the No. 1 switch hole base
     
    4 steering column-to-instrument panel nuts, disconnect the spring from the brake pedal and remove the steering column
     
    Instrument cluster finish panel using a suitable prytool
     
    4 instrument cluster-to-instrument panel screws, disconnect the electrical connectors and remove the instrument cluster
     
    No. 2 undercover using a suitable prytool
     
    Plate and disconnect the air bag electrical connector inside the glove box
     
    Glove box-to-instrument panel 2 bolts, 3 screws, and the glove box
     
    3 CD changer-to-instrument panel nuts, disconnect the electrical connectors and remove the CD changer
     
    Ashtray
     
    No. 2 register using a suitable prytool and disconnect the connector
     
    Audio unit-to-instrument panel 2 bolts, 2 screws and the audio unit
     
    Cluster finish panel using a suitable prytool, disconnect the connectors and remove the panel.
     
    Console box carpet
     
    Lower rear console box
     
    Rear console armrest
     
    No. 3 console box mounting bracket
     
    Console box
     
    No. 1 console box duct
     
    No. 7 heater-to-register
     
    5 instrument panel-to-chassis bolts, the nut, the screw and the instrument panel
     
    No. 1 and No. 2 brace
     
    Reinforcement-to-chassis 5 nuts, 4 bolts and the reinforcement
     
    Ventilation nozzles from the heater/air conditioning housing
     

  12.  
  13. Remove the blower unit by removing or disconnecting the following:

    Connector clamp
     
    3 air duct-to-blower housing screws and the air duct
     
    Electrical connector bracket, the wiring harness clamps and the wiring harness
     
    Blower housing connectors
     
    2 blower housing-to-bracket bolts and the bracket
     
    Blower housing-to-chassis bolt, screw, nut and the blower housing
     

  14.  
  15. Remove or disconnect the following:

    2 center air duct-to-heater/air conditioning housing screws and the air duct
     
    Move the floor carpet rearward
     
    Wiring harness clamps
     
    2 air duct bolts and the ducts at both sides
     

  16.  
  17. Remove the heater/air conditioning housing by removing or disconnecting the following:

    Electrical connector
     
    Wiring harness set nut
     
    Wiring harness clamp
     
    Heater/air conditioning housing 2 nuts and bolt
     
    Heater/air conditioning housing
     

  18.  
  19. Remove the heater core-to-heater/air conditioning housing clamp screw and the clamp.
  20.  
  21. Pull the heater core from the heater/air conditioning housing.

    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel and related components-GS 300 and 1998-01 GS 400



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel, ventilation ducts and related components-GS 300 and 1998-01 GS 400



    Click image to see an enlarged view

    Fig. Exploded view of the heater/air conditioning housing and related components-GS 300 and 1998-01 GS 400



    Click image to see an enlarged view

    Fig. Exploded view of the heater core, heater housing and related components-GS 300 and 1998-01 GS 400

  22.  

To install:

  1. Install the heater core to the heater/air conditioning housing.
  2.  
  3. Install the heater core clamp and the clamp-to-heater/air conditioning housing screw.
  4.  
  5. Install the heater/air conditioning housing by installing or connecting the following:

    Heater/air conditioning housing
     
    Heater/air conditioning housing 2 nuts and bolt
     
    Wiring harness clamp
     
    Wiring harness set nut
     
    Electrical connector
     

  6.  
  7. Install or connect the following:

    Air duct and the 2 duct bolts on both sides
     
    Wiring harness clamps
     
    Move the floor carpet forward
     
    Center air duct and the 2 air duct-to-heater/air conditioning housing screws
     

  8.  
  9. Install the blower unit by installing or connecting the following:

    Blower housing and the blower housing-to-chassis bolt, screw and nut
     
    Blower housing and the 2 bracket-to-bracket bolts
     
    Blower housing connectors
     
    Electrical connector bracket, the wiring harness clamps and the wiring harness
     
    Air duct and the 3 air duct-to-blower housing screws
     
    Connector clamp
     

  10.  
  11. Install the instrument by installing or connecting the following:

    Ventilation nozzles to the heater/air conditioning housing
     
    Reinforcement and the reinforcement-to-chassis 5 nuts and 4 bolts
     
    No. 1 and No. 2 brace
     
    Instrument panel and the 5 instrument panel-to-chassis bolts, the nut and the screw
     

  12.  
  13. Install or connect the following:

    No. 7 heater-to-register
     
    No. 1 console box duct
     
    Console box
     
    No. 3 console box mounting bracket
     
    Rear console armrest
     
    Lower rear console box
     
    Console box carpet
     
    Connectors and install the cluster finish panel
     
    Audio unit and the audio unit-to-instrument panel 2 bolts and 2 screws
     
    Connector and install the No. 2 register
     
    Ashtray
     
    CD changer, connect the electrical connectors and install the 3 CD changer-to-instrument panel nuts
     
    Glove box and the glove box-to-instrument panel 2 bolts and 3 screws
     
    Air bag electrical connector and install the plate inside the glove box
     
    No. 2 undercover
     
    Instrument cluster, connect the electrical connectors and install the 4 instrument cluster-to-instrument panel screws
     
    Instrument cluster finish panel
     
    Steering column, connect the spring to the brake pedal and install the 4 steering column-to-instrument panel nuts
     
    Parking brake handle and the No. 1 switch hole base
     
    No. 1 safety pad and the 4 safety pad-to-instrument panel bolts and screw
     
    Hood lock release and the 2 release screws
     
    No. 1 undercover and the 2 undercover-to-instrument panel screws
     
    End pad
     
    Combination switch and connect the electrical connectors
     
    Steering column covers and the cover screws
     
    Front pillar garnishes and the front door scuff plates
     

  14.  
  15. Install the steering wheel by installing or connecting the following:

    Steering wheel and torque the steering wheel nut to 26 ft. lbs. (35 Nm)
     
    Electrical connector and install the air bag
     
    Tighten the Torx bolts to 80 inch lbs. (9.0 Nm) using a Torx wrench
     
    Torx bolt covers at both sides of the steering wheel
     
    No. 1 grommet, the heater pipe grommet and the drain hose grommet
     
    Heater hoses to the heater core
     
    Refrigerant lines (using new O-rings) and the refrigerant lines-to-evaporator bolt
     

  16.  
  17. Refill the cooling system.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Evacuate, charge and leak test the air conditioning system refrigerant.
  22.  
  23. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  24.  

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.  

SC 300 And SC 400




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

  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. Discharge and recover the air conditioning system refrigerant.
  6.  
  7. Remove or disconnect the following:

    Refrigerant lines from the evaporator. Discard the O-rings. Plug the lines to prevent contamination
     
    Heater hoses from the heater core
     
    Brake tubes mounting bolts
     
    Heater water valve and the ABS actuator
     
    Equalizer tube from the EPR, discard the O-ring and plug the openings to prevent contamination
     
    2 insulator retainer bolts and the retainer at the heater core
     

  8.  
  9. Remove the steering wheel by removing or disconnecting the following:

    Place the front wheels in the straight-ahead position
     
    Torx bolt covers at both sides of the steering wheel
     
    Loosen the Torx bolts (using a Torx wrench) until the circumference ring on the bolt catches on the screw case
     
    Lift the air bag, disconnect the electrical connector and remove it
     
    Steering wheel nut and press the steering wheel from the steering column
     

  10.  
  11. Remove the instrument panel and reinforcement by removing or disconnecting the following:

    Tilt the steering column down and pull out the steering wheel
     
    Front assist grips
     
    Front pillar garnishes and the front scuff plates
     
    Steering column cover
     
    Shift lever knob
     
    Upper console panel rear
     
    Upper console panel
     
    Radio with the air conditioning control assembly
     
    No. 2 undercover
     
    Finish plate and disconnect the air bag electrical connector located inside the glove box
     
    Glove compartment assembly
     
    4 lower right side finish panel bolts and the panel
     
    No. 4 heater-to-register duct screw and the duct
     
    Passenger-s side air bag module-to-instrument panel 3 bolts and 2 nuts; then, remove the air bag
     
    No. 4 undercover-to-instrument panel cover screws and the cover
     
    Console box
     
    End pad at the left side of the instrument panel
     
    key center plate and the center pad
     
    2 hood release lever screws and the lever
     
    3 No. 1 lower finish panel screws, disconnect the electrical connectors and remove the panel
     
    4 lower left side finish panel bolts and the panel
     
    No. 2 heater-to-register duct
     
    Combination switch
     
    Cluster finish panel
     
    Combination meter
     
    Steering column assembly
     
    Instrument panel-to-chassis fasteners and the instrument panel
     
    Instrument panel reinforcement fasteners and the reinforcement
     

  12.  
  13. Remove or disconnect the following:

    PPS ECU
     
    Cooling fan ECU
     
    ABS ECU
     
    Move the floor carpet rearward
     
    Heater-to-No. 3 duct register screw and the duct
     
    2 connector bracket screws and the bracket at the under side of the blower motor
     
    Electrical connector; then, remove the 6 heater/air conditioning housing-to-chassis bolts and the housing
     
    2 heater core plate-to-heater housing screws and the plate
     
    2 heater core clamp screws and the clamps
     
    Heater core

    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel and related components-SC 300 and SC 400



    Click image to see an enlarged view

    Fig. Exploded view of the heater/air conditioning housing, reinforcement, ventilation ducts and related components-SC 300 and SC 400



    Click image to see an enlarged view

    Fig. Exploded view of the heater core, heater/air conditioning housing and related components-SC 300 and SC 400

     

  14.  

To install:

  1. Install or connect the following:

    Heater core
     
    Heater core clamps and the 2 clamp screws
     
    Heater core plate and the 2 plate-to-heater housing screws
     
    Electrical connector; then, install the heater/air conditioning housing and the 6 housing-to-chassis bolts
     
    Connector bracket and the 2 bracket screw at the under side of the blower motor
     
    Heater-to-No. 3 duct register and the duct screw
     
    Floor carpet forward
     
    ABS ECU
     
    Cooling fan ECU
     
    PPS ECU
     

  2.  
  3. Install the instrument panel and reinforcement by installing or connecting the following:

    Instrument panel reinforcement and the reinforcement fasteners
     
    Instrument panel and the instrument panel-to-chassis fasteners
     
    Steering column assembly
     
    Combination meter
     
    Cluster finish panel
     
    Combination switch
     
    No. 2 heater-to-register duct
     
    Lower left side finish panel and the 4 panel bolts
     
    No. 1 lower finish panel, connect the electrical connectors and install the 3 panel screws
     
    Hood release lever and the 2 lever screws
     
    key center plate and the center pad
     
    End pad at the left side of the instrument panel
     
    Console box
     
    No. 4 undercover-to-instrument panel cover and the cover screws
     
    Passenger-s side air bag module and torque the air bag-to-instrument panel 3 bolts and 2 nuts to 15 ft. lbs. (21 Nm)
     
    No. 4 heater-to-register duct and the duct screw
     
    Lower right side finish panel and the 4 panel bolts
     
    Glove compartment assemble
     
    Air bag electrical connector and install the finish plate inside the glove box
     
    No. 2 undercover
     
    Radio with the air conditioning control assembly
     
    Upper console panel
     
    Upper console panel rear
     
    Shift lever knob
     
    Steering column cover
     
    Front pillar garnishes and the front scuff plates
     
    Front assist grips
     

  4.  
  5. Install the steering wheel by installing or connecting the following:

    Steering wheel and torque the steering wheel nut to 26 ft. lbs. (35 Nm)
     
    Electrical connector and install the air bag
     
    Torx bolts to 80 inch lbs. (9.0 Nm) using a Torx wrench
     
    Torx bolt covers at both sides of the steering wheel
     

  6.  
  7. Install or connect the following:

    Insulator retainer and the 2 retainer bolts at the heater core
     
    Equalizer tube to the EPR using a new O-ring
     
    Heater water valve and the ABS actuator
     
    Brake tubes mounting bolts
     
    Heater hoses to the heater core
     
    Refrigerant lines to the evaporator using new O-rings
     

  8.  
  9. Refill the cooling system.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Evacuate, charge and leak test the air conditioning system refrigerant
  14.  
  15. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  16.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Discharge the A/C system.
  4.  
  5. Drain the cooling system into a clean container for reuse.
    NOTE
    It is not necessary to drain out all coolant.

  6.  
  7. Set the temperature control switch to MAX cool.
  8.  
  9. Remove the brake tubes mounting bolts.
  10.  
  11. Remove the water valve as follows:


    1. Remove the 2 bolts.
    2.  
    3. Loosen the hose band, then pull off the water hose.
    4.  

  12.  
  13. Remove the ABS actuator as follows:


    1. Using SST 09023-00100, disconnect the brake lines from the ABS actuator.
    2.  
    3. Disconnect the 2 connectors.
    4.  
    5. Remove the bolt, 3 nuts and ABS actuator assembly.
    6.  
    7. Remove the 2 nuts and ABS actuator.
    8.  
    9. Remove the 2 cushion bolts and 3 cushions.
    10.  

  14.  
  15. Remove the 2 bolts and disconnect the liquid and suction tubes. Cap the open fittings immediately to keep moisture or dirt out of the system.
  16.  
  17. Remove the bolt and disconnect the equalizer tube from the EPR. Cap the open fittings immediately to keep moisture or dirt out of the system.
  18.  
  19. Disconnect the water hose from the heater core (heater radiator).
  20.  
  21. Remove the 2 bolts and the insulator retainer.
  22.  
  23. Remove the instrument panel and reinforcement assemblies.
  24.  
  25. Remove the PPS ECU.
  26.  
  27. Remove the cooling fan ECU.
  28.  
  29. Remove the ABS ECU.
  30.  
  31. Slide the floor carpet back.
  32.  
  33. Remove the nut and the rear air ducts.
  34.  
  35. Remove the screw and the heater-to-resister No. 3 duct.
  36.  
  37. Remove the 2 screws and the connector bracket from underside of blower motor.
  38.  
  39. Remove the A/C unit as follows:


    1. Disconnect the connectors from the unit.
    2.  
    3. Remove the 6 bolts and the A/C unit.
    4.  

  40.  
  41. Remove the heater core (heater radiator) from the A/C unit as follows:


    1. Remove the 2 screws and the plate.
    2.  
    3. Remove the 2 screws and the clamps.
    4.  
    5. Pull out the radiator.

      Click image to see an enlarged view

      Fig. Exploded view of the A/C unit assembly, instrument panel reinforcement and related components-SC 300 and SC 400



      Click image to see an enlarged view

      Fig. Exploded view of the heater radiator unit (heater core), heater housing and related components-SC 300 and SC 400

    6.  

  42.  

To install:

  1. Install the heater core into the A/C unit.
  2.  
  3. Install the A/C unit into the vehicle.
  4.  
  5. Install the connector bracket to the underside of blower motor.
  6.  
  7. Install the heater-to-resister No. 3 duct.
  8.  
  9. Install the rear air ducts.
  10.  
  11. Position the floor carpet back.
  12.  
  13. Install the ABS ECU.
  14.  
  15. Install the cooling fan ECU.
  16.  
  17. Install the PPS ECU.
  18.  
  19. Install the instrument panel and reinforcement assemblies.
  20.  
  21. Install the insulator retainer.
  22.  
  23. Connect the water hose to the heater core.
  24.  
  25. Connect the equalizer tube to the EPR. Lubricate a new O-ring with compressor oil and install them to the tube. Tighten the bolt to 17 ft. lbs. (23 Nm).
  26.  
  27. Connect the liquid and suction tubes. Lubricate 2 new O-rings with compressor oil and install them to the tubes. Tighten the 2 bolts to 7 ft. lbs. (10 Nm).
  28.  
  29. Install the ABS actuator as follows:


    1. Install the 3 cushions and 2 cushion bolts.
    2.  
    3. Install the ABS actuator and tighten the 2 nuts to 48 inch lbs. (5.4 Nm).
    4.  
    5. Install the ABS actuator assembly. Tighten the bolt and 3 nuts to 14 ft. lbs. (19 Nm).
    6.  
    7. Connect the 2 connectors.
    8.  
    9. Connect the brake lines to the ABS actuator. Tighten the fittings to 11 ft. lbs. (15 Nm).
    10.  

  30.  
  31. Install the water valve as follows:


    1. Push the water hose onto the water valve pipe until the pipe is completely hidden.
    2.  
    3. Install the hose band in a position where about 0.039 inch (1mm) of the marking on the hose can be seen. Tighten the hose band.
    4.  
    5. Install the 2 bolts.
    6.  

  32.  
  33. Install the brake tubes mounting bolts.
  34.  
  35. Fill cooling system with coolant.
  36.  
  37. Connect the negative battery cable.
  38.  
  39. Evacuate and recharge A/C system.
  40.  
  41. Warm up engine and inspect for coolant leaks.
  42.  

SC 430




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. Discharge and recover the air conditioning system refrigerant.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Do Not use pry tools to separate. Cap the end to prevent system contamination



    A/C Suction and pressure hose bolt and plate at firewall
     



    Heater hoses from the heater core
     

  8.  
  9. 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-
     

  10.  
  11. Disconnect the negative battery cable. Wait 90 seconds before doing any further work while the airbag system de-energizes.
  12.  
  13. Center the front wheels and steering wheel.
  14.  
  15. Remove the instrument panel assembly.
  16.  
  17. Remove the air conditioning unit assembly as follows:

    Wire harness clamps and disconnect wire harness from air conditioning unit assembly
     
    2 screws, 3 nuts, bolt and air conditioning unit
     

  18.  
  19. Remove the heater bracket.
  20.  
  21. Remove the air conditioning evaporator assembly as follows:

    Connector and clamp for the blower assembly
     
    Release claw and disconnect the connector from the bracket
     
    2 screws and release the claw or the evaporator assembly
     
    evaporator assembly
     

  22.  
  23. Disconnect the cooler thermistor hose.
  24.  
  25. Remove air duct No.1, 2, 3 and 4.
  26.  
  27. Remove heater core unit sub-assembly as follows:

    Screw and clamp
     
    Heater core assembly from A/C assembly

    Click image to see an enlarged view

    Fig. View of the Heater & Air Conditioning assembly-SC 430



    Click image to see an enlarged view

    Fig. Exploded view of Heater & Air Conditioning assembly-SC 430

     

  28.  

To install:

  1. Install the heater core unit sub-assembly as follows:

    Heater core into A/C assembly
     
    Screw and clamp
     

  2.  
  3. Install air duct No. 1,2, 3 and 4.
  4.  
  5. Connect the cooler thermistor hose.
  6.  
  7. Install the air conditioning unit assembly as follows:

    2 screws and 3 nuts and air conditioning unit
     
    Bolt to air conditioning unit assembly. Torque: 87 inch lbs. (9.8 Nm)
     
    Clamps to the air conditioner unit assembly
     

  8.  
  9. Install the instrument panel assembly.
  10.  
  11. Connect the heater core hoses.
  12.  
  13. Connect the A/C suction and pressure hoses, attach with bolt and plate.
    NOTE
    Lubricate O-rings with compressor oil

  14.  
  15. Connect the negative battery cable.
  16.  
  17. Fill cooling system with coolant.
  18.  
  19. Evacuate and recharge A/C system.
  20.  
  21. Warm up engine and inspect for coolant leaks.
  22.  

 
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