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Home >> Lexus Truck >> 2010 >> RX 350 AWD V6-3.5L (2GR-FE) >> Repair and Diagnosis >> Heating and Air Conditioning >> Housing Assembly HVAC >> Service and Repair >> Removal and Replacement >> Installation >> From 08/2009

From 08/2009





HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT: INSTALLATION

1. INSTALL AIR CONDITIONING UNIT ASSEMBLY

(a) Install the air conditioning unit assembly with the 3 bolts in the order shown in the illustration.





Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

NOTICE:
Tighten the bolts in the order shown in the illustration to install the air conditioning unit assembly.

2. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY

(a) Engage the 4 claws to install the No. 1 air duct sub-assembly.





3. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT ASSEMBLY

(a) Using a "TORX" socket wrench (T40), install the instrument panel reinforcement assembly with the 5 "TORX" bolts in the order shown in the illustration.

Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)

NOTICE:
Tighten the bolts in the order shown in the illustration to install the reinforcement assembly.

(b) Install the 5 instrument panel safety pad caps.





Text in Illustration





(c) Install the 2 bolts and 2 caps to engine compartment side.

Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)

(d) Install the instrument panel reinforcement assembly with air conditioning unit assembly with the nut.

Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

(e) Connect the cooler drain hose as shown in the illustration.

NOTICE:
Connect the cooler drain hose firmly to prevent water leaks.





Text in Illustration





(f) Engage each clamp.

(g) Install the bolt and connect the earth wire.

Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

(h) Connect the connector holder with the nut.

Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)

(i) Connect the connector.

(j) Connect the blower motor connector.

(k) Connect the 2 air conditioning ECU connectors.





Text in Illustration





(l) Engage each clamp.

(m) Connect the earth wire with the bolt.

Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

(n) Connect each connector.





Text in Illustration





4. INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

(a) Install the 2 bolts and 2 nuts.





Bolt - Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)

Nut - Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)

(b) Install the No. 2 instrument panel brace sub-assembly with the screw.

(c) Engage each clamp.

Text in Illustration





5. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

(a) Install the 2 bolts and 2 nuts.





Bolt - Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)

Nut - Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)

(b) Install the No. 1 instrument panel brace sub-assembly with the screw.

(c) Engage each clamp.

Text in Illustration





6. INSTALL NO. 5 INSTRUMENT PANEL BRACKET (w/o Navigation System for HDD)

(a) Install the 2 No. 5 instrument panel brackets.





7. INSTALL CENTER HEATER TO REGISTER SUB DUCT

(a) Install the center heater to register sub duct with the 3 clips.





8. INSTALL REAR NO. 3 AIR DUCT

(a) Engage the 2 claws to install the rear No. 3 air duct.





9. INSTALL REAR NO. 4 AIR DUCT

(a) Engage the claw to install the rear No. 4 air duct.





(b) Install the clip.

(c) Engage the claw and 2 clamps.





(d) Engage the fastener to install the floor carpet to the original position.

Text in Illustration





10. INSTALL FRONT FLOOR CAUTION PLATE COVER (for TMC Made)

(a) Engage the guide as shown in the illustration.





(b) Engage the claw to install the frame number cover.





11. INSTALL REAR NO. 1 AIR DUCT

(a) Engage the 2 claws to install the rear No. 1 air duct.





(b) Engage the clamp.

12. INSTALL REAR NO. 2 AIR DUCT

(a) Engage the claw to install the rear No. 2 air duct.





(b) Install the clip.

(c) Engage the claw and 2 clamps.





(d) Engage the fastener to install the floor carpet to the original position.

Text in Illustration





13. INSTALL ECU INTEGRATION BOX Installation

14. INSTALL DISPLAY AND NAVIGATION MODULE DISPLAY WITH BRACKET (w/ Navigation System for HDD) Installation

15. INSTALL CLEARANCE WARNING BUZZER Installation

16. INSTALL TURN SIGNAL FLASHER ASSEMBLY Installation

17. REMOVE POWER STEERING ECU ASSEMBLY Installation

18. INSTALL DRIVER SIDE JUNCTION BLOCK ASSEMBLY Installation

19. INSTALL NO. 3 INSTRUMENT PANEL STAY Installation

20. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY Installation

21. CONNECT INSTRUMENT PANEL WIRE ASSEMBLY Installation

22. INSTALL NO. 1 CONSOLE BOX DUCT Installation

23. INSTALL SHIFT LEVER ASSEMBLY Installation

24. INSTALL NO. 1 DEFROSTER NOZZLE GARNISH Installation

25. INSTALL FRONT NO. 4 SPEAKER ASSEMBLY Installation

26. INSTALL NO. 1 SPEAKER OPENING COVER ASSEMBLY Installation

27. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY Installation

28. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY Installation

29. INSTALL FRONT PILLAR GARNISH LH Installation

30. INSTALL INSTRUMENT SIDE PANEL LH Installation

31. INSTALL FRONT PILLAR GARNISH RH Installation

32. INSTALL INSTRUMENT SIDE PANEL RH Installation

33. INSTALL GLASS BREAKAGE SENSOR ECU Installation

34. INSTALL REMOTE ENGINE STARTER ECU Installation

35. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY Installation

36. INSTALL FRONT PASSENGER SIDE KNEE AIRBAG ASSEMBLY Installation

37. INSTALL INSTRUMENT PANEL GARNISH RH Installation

38. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY Installation

39. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH Installation

40. INSTALL FRONT DOOR SCUFF PLATE RH Installation

41. INSTALL CONSOLE BOX Installation

42. INSTALL RADIO RECEIVER ASSEMBLY WITH REGISTER Installation

43. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL Installation

44. INSTALL INSTRUMENT PANEL FINISH PANEL Installation

45. INSTALL MULTI-DISPLAY ASSEMBLY (w/ Navigation System) Installation

46. INSTALL ACCESSORY METER ASSEMBLY (w/o Navigation System) Installation

47. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL Installation

48. INSTALL COMBINATION METER ASSEMBLY Installation

49. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL Installation

50. INSTALL NO. 1 INSTRUMENT PANEL HOLE COVER Installation

51. INSTALL NO. 2 INSTRUMENT PANEL HOLE COVER Installation

52. INSTALL STEERING POST ASSEMBLY Installation

53. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY Installation

54. INSTALL BRAKE PEDAL SUPPORT ASSEMBLY Installation

55. CONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS Installation

56. INSTALL BRAKE PEDAL RETURN SPRING Installation

57. INSTALL STOP LIGHT SWITCH ASSEMBLY Installation

58. INSPECT AND ADJUST BRAKE PEDAL HEIGHT Adjustments

59. INSPECT BRAKE PEDAL FREE PLAY Adjustments

60. INSPECT BRAKE PEDAL RESERVE DISTANCE Adjustments

61. INSTALL NO. 4 AIR DUCT SUB-ASSEMBLY Installation

62. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY Installation

63. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY Installation

64. INSTALL NO. 1 SWITCH HOLE BASE Installation

65. INSTALL INSTRUMENT PANEL GARNISH LH Installation

66. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY Installation

67. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH Installation

68. INSTALL FRONT DOOR SCUFF PLATE LH Installation

69. INSTALL REAR CONSOLE BOX ASSEMBLY Installation

70. INSTALL MULTI-MEDIA INTERFACE ECU ASSEMBLY (w/ USB Audio System) Installation

71. INSTALL CONSOLE REAR END PANEL SUB-ASSEMBLY Installation

72. INSTALL NO. 2 CONSOLE BOX DUCT Installation

73. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY Installation

74. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY Installation

75. INSTALL TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY Installation

76. INSTALL UPPER STEERING COLUMN COVER Installation

77. INSTALL LOWER STEERING COLUMN COVER Installation

78. ADJUST SPIRAL CABLE Installation

79. INSTALL STEERING WHEEL ASSEMBLY Installation

80. INSPECT STEERING WHEEL CENTER POINT

81. INSTALL STEERING PAD Installation

82. INSTALL LOWER NO. 3 STEERING WHEEL COVER Installation

83. INSTALL LOWER NO. 2 STEERING WHEEL COVER Installation

84. CONNECT INLET HEATER WATER HOSE

(a) Using pliers, grip the claws of the clip and slide the clip to connect the inlet heater water hose.





85. CONNECT OUTLET HEATER WATER HOSE

(a) Using pliers, grip the claws of the clip and slide the clip to connect the outlet heater water hose.





86. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY

(a) Remove the attached vinyl tape from the pipe.

(b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioning tube and accessory assembly.

Compressor oil:

ND-OIL 8 or equivalent

(c) Install the O-ring on the air conditioning tube and accessory assembly.

NOTICE:
Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign objects.

(d) Install the air conditioning tube and accessory assembly.

87. CONNECT SUCTION PIPE SUB-ASSEMBLY

(a) Remove the attached vinyl tape from the pipe.

(b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction pipe sub-assembly.

Compressor oil:

ND-OIL 8 or equivalent

(c) Install the O-ring on the suction pipe sub-assembly.

NOTICE:
Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign objects.

(d) Install the suction pipe sub-assembly.

(e) Move the hook connector in the direction indicated by the arrow in the illustration.





(f) Insert the pipe joint into the fitting hole securely and tighten the bolt.

Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

(g) Engage the 6 clamps to the engine wire harness.





88. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY Installation

89. INSTALL FRONT SHOCK ABSORBER CAP LH (w/ Air Suspension) Installation

90. INSTALL FRONT SHOCK ABSORBER CAP RH (w/ Air Suspension)

HINT
Use the same procedure for the RH side and LH side.

91. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation

92. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation

93. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation

94. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation

95. INSTALL FRONT WIPER ARM HEAD CAP Installation

96. INSTALL FRONT FENDER TO COWL SIDE SEAL RH Installation

97. INSTALL FRONT FENDER TO COWL SIDE SEAL LH Installation

98. INSTALL FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY RH Installation

99. INSTALL FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY LH Installation

100. INSTALL FRONT SEAT ASSEMBLY

(a) for LH Side:

(1) Refer to the procedure from Install Front Seat Assembly Installation.

(b) for RH Side:

HINT
Use the same procedure for the RH side and LH side.

101. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:
* Make sure that the cable has been disconnected from the negative (-) battery terminal for at least 2 seconds before reconnecting the cable.
* Reset the auto tilt away function setting to the previous condition by changing the customize parameter Programming and Relearning.
* When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.
102. INSTALL FRONT WHEEL LH Installation

103. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

104. ADD ENGINE COOLANT Service and Repair

105. CHARGE WITH REFRIGERANT Service and Repair

106. WARM UP ENGINE Service and Repair

107. INSPECT FOR REFRIGERANT LEAK Service and Repair

108. INSPECT FOR COOLANT LEAK Testing and Inspection

109. INSTALL COOL AIR INTAKE DUCT SEAL Installation

110. INSTALL ENGINE ROOM SIDE COVER Installation

111. INSTALL ENGINE ROOM SIDE COVER LH Installation

112. INSPECT SHIFT LEVER POSITION

for U660F: U660F Automatic Transaxle

for U660E: U660E Automatic Transaxle

113. ADJUST SHIFT LEVER POSITION

for U660F: U660F Automatic Transaxle

for U660E: U660E Automatic Transaxle

114. INSPECT STEERING PAD Installation

115. INSPECT SUSPENSION CONTROL SYSTEM (w/ Air Suspension)

(a) Inspect the suspension control system Test Mode Procedure.

116. INSPECT SRS WARNING LIGHT

(a) Inspect the SRS warning light Diagnosis System.
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