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Air Conditioning Unit: Disassembly

WARNING: This page is about a different car, the 2003 Lexus RX 300. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE AIR OUTLET SERVOMOTOR 
    1. Disconnect the connector.
    2. Remove the 2 screws and servomotor.
    Fig 1: Removing Air Outlet Servomotor
    G01331161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE WIRE HARNESS 
  3. REMOVE BRACKET 

    Remove the bolt and bracket.

    Fig 2: Removing Wire Harness
    G01331162Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE HEATER RADIATOR 
    1. Remove the 2 screws and 2 plates.
    2. Pull out the heater radiator.
    Fig 3: Removing Heater Radiator
    G01331163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE BLOWER MOTOR CONTROL RELAY 

    Remove the screw and blower motor control relay.

    Fig 4: Removing Blower Motor Control Relay
    G01331164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE AIR MIX SERVOMOTOR 

    Remove the 2 screws and servomotor.

    Fig 5: Removing Air Mix Servomotor
    G01331165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE EVAPORATOR TEMPERATURE SENSOR 
    1. Disconnect the connector clamp.
    2. Using a screwdriver, pull out the sensor.

      HINT:

      Tape the screwdriver tip before use.

      Fig 6: Removing Evaporator Temperature Sensor
      G01331166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Release the 2 claws and remove the sensor from bracket plate.
    Fig 7: Removing Sensor From Bracket Plate
    G01331167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE EXPANSION VALVE 
    1. Pry out the packings.

      HINT:

      At the time of reassembly, please refer to the following item. Do not reuse the packing.

    2. Using a hexagon wrench (5.0 mm, 0.20 in.), remove the 2 bolts, then separate the tube connector, expansion valve and tube.
      1. Torque: 4.1 N.m (42 kgf.cm, 36 in.lbf) 
    NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system.

    HINT:

    At the time of reassembly, please refer to the following item. Lubricate 4 new O-rings with compressor oil and install them to the valve.

    Fig 8: Removing Expansion Valve
    G01331168Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE AIR DUCT (Driver Side) 
    Fig 9: Removing Air Duct (Driver Side)
    G01331169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE EVAPORATOR 
    1. Using a hexagon wrench (5.0 mm, 0.20 in.), remove the 2 bolts and tube and accessory.
      1. Torque: 4.1 N.m (42 kgf.cm, 36 in.lbf) 
      NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system.

      HINT:

      At the time of installation, please refer to the following item.

      Lubricate 2 new O-rings with compressor oil and install them to the tube.

      Fig 10: Removing Bolts Tube And Accessory
      G01331170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 7 screws and cover.
    3. Pull out the evaporator.

      HINT:

      At the time of reassembly, please refer to the following item. If evaporator is replaced, add compressor oil to the evaporator.

      1. Add40cc(1.4fl. oz.) 
      2. Compressor oil: ND-OIL 8 or equivalent 
    4. Remove the insulator.
      Fig 11: Removing Evaporator
      G01331171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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