Air Conditioner Control Assembly: Overhaul

WARNING: This page is about a different car, the 2004 Lexus SC 430. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: When disassembling air conditioner control assembly, measures should be taken to prevent static electricity from damaging the system.

HINT:

COMPONENTS: See COMPONENTS

REMOVE AIR CONDITIONER CONTROL ASSY
1. Pull the air conditioner control assy towards the rear of the vehicle and disengage the 6 clip fittings.
2. Disconnect the 3 connectors and remove the air conditioner control assy.
  
  Fig 1: Disconnecting Connectors & Removing Air Conditioner Control Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CONSOLE UPPER PANEL GARNISH FRONT
1. Remove the 2 screws.
2. Disengage the 2 claw fittings and remove the console upper panel garnish FR from the air conditioner control assy.
  
  Fig 2: Disengaging Claw Fittings & Removing Console Upper Panel Garnish FR From Air Conditioner Control Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HEATER CONTROL HOUSING
1. Remove the 6 screws and disengage the 4 claw fittings. Then separate the heater control housing.
  
  Fig 3: Removing Screws & Disengaging Claw Fittings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the 2 cooler wires NO.1 and remove the heater control housing
  
  Fig 4: Disconnecting Cooler Wires No.1 & Removing Heater Control Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR CONDITIONER AMPLIFIER ASSY
1. Remove the 2 screws, cover plate and water-protective sheet.
  
  Fig 5: Removing Screws, Cover Plate & Water-Protective Sheet
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE COOLER WIRE NO.1
1. Remove the air conditioner amplifier assy.
2. Disconnect the 2 cooler wires No.1.
  
  Fig 6: Disconnecting Cooler Wires No.1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE COOLER WIRE NO.1 (W/ LEXUS NAVIGATION SYSTEM)
1. Disconnect the cooler wire No.1 from the air conditioner panel.
  
  Fig 7: Disconnecting Cooler Wire No.1 From Air Conditioner Panel
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HEATER CONTROL BASE SUB-ASSY
1. Remove the 2 screws.
  
  Fig 8: Removing Heater Control Base Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a thin Flathead screwdriver with the tip taped up with protective tape, disengage the 7 claw fittings in the order shown in Fig 9 .
  HINT:
  
  Bend the film (Black) forward to insert the flathead screwdriver from underneath the base into claw fittings (4) and (7) as shown in Fig 9 and then disengage these fittings.
  
  Fig 9: Identifying Order Of Disengaging Claw Fittings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. With all the claw fittings disengaged, face the heater control base upward as shown in Fig 10 .
  
  Fig 10: Facing Heater Control Base Upward
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Slowly remove the heater control base.
  NOTE: If the heater control base is removed while facing down, the control knob may fall off.
  
  Fig 11: Removing Heater Control Base
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MULTI-DISPLAY JUNCTION BLOCK (W/LEXUS NAVIGATION SYSTEM)
1. Remove the 2 screws and the multi-display junction block.
  
  Fig 12: Removing Screws & Multi-Display Junction Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HEATER CONTROL KNOB
1. Remove the heater control knob.
  
  Fig 13: Removing Heater Control Knob
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HEATER CONTROL KNOB
1. Install the heater control knob as shown in Fig 14 .
  NOTE: Be sure to install the heater control knob in the correct direction if it falls off.
  
  Fig 14: Installing Heater Control Knob
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MULTI-DISPLAY JUNCTION BLOCK (W/LEXUS NAVIGATION SYSTEM)
1. Install the multi-display junction block with the 2 screws.
  
  Fig 15: Installing Multi-Display Junction Block With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HEATER CONTROL BASE SUB-ASSY
1. Engage the 7 claw fittings and install the heater control base on the control switch assy.
  
  Fig 16: Engaging Claw Fittings & Installing Heater Control Base On Control Switch Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful not to damage the display.
  
  HINT:
  
  Ensure to push the 2 claw fittings shown in Fig 17 .
  
  Fig 17: Pushing Claw Fittings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 2 screws.
  
  Fig 18: Installing Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR CONDITIONER AMPLIFIER ASSY
1. Connect the 2 cooler wires No.1 to the air conditioner amplifier assy.
  NOTE: Be sure to connect the wires with the sides marked in black to the air condition amplifier assy side.
2. Push on the locking parts of the connectors to secure the cooler wires No.1.
  
  Fig 19: Pushing On Locking Parts Of Connectors To Secure Cooler Wires No.1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the air conditioner amplifier assy with the 2 screws, cover plate and water-protective sheet.
  NOTE:
  - Be sure to fit the base to the groove on the cover plate.
  - Insert the water-protective sheet into the heater control housing as shown in Fig 20 .
  Fig 20: Installing Air Conditioner Amplifier Assy With Screws, Cover Plate & Water-Protective Sheet
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HEATER CONTROL HOUSING
1. Connect the 2 cooler wires No.1 to the heater control housing.
2. Push on the locking parts of the connectors to secure the cooler wires No.1.
  
  Fig 21: Pushing On Locking Parts Of Connectors To Secure Cooler Wires No.1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Engage the 4 claw fittings and install the heater control housing with the 6 screws.
  
  Fig 22: Engaging Claw Fittings & Installing Heater Control Housing With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002