Front Cooling Unit: Disassembly

WARNING: This page is about a different car, the 2004 Lexus LX 470. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE EVAPORATOR
1. Disconnect the connector clamp.
2. Remove the 8 screws and No. 1 cooler cover.
3. Pull out the evaporator
  
  Fig 1: Removing Evaporator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  At the time of reassembly, if evaporator is replaced, add compressor oil to the evaporator.
  
  Add: 40 cc (1.4 fl.oz.)
  
  Compressor oil: ND-OIL 8 or equivalent
4. Pull out the air refiner filter.
PULL OUT EVAPORATOR TEMPERATURE SENSOR FROM EVAPORATOR

Fig 2: Removing Evaporator Temperature Sensor From Evaporator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXPANSION VALVE
1. Remove the grommet.
2. Pry out the packing.
  
  Fig 3: Removing Expansion Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  At the time of reassembly, do not reuse the packing.
3. Using a hexagon wrench (5.0 mm, 0.20 in.), remove the 2 bolts and separate the expansion valve, tube and evaporator.
  Torque: 3.4 N.m (35 kgf.cm, 30 in.lbf)
NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system.

HINT:

At the time of reassembly, lubricate 4 new O-rings with compressor oil and install them in the tube.
REMOVE DRAIN HOSE