Air Conditioning Unit: Disassembly

WARNING: This page is about a different car, the 2003 Lexus LS 430. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE DRAIN HOSES
REMOVE ASPIRATOR
REMOVE EVAPORATOR TEMPERATURE SENSOR
REMOVE TUBE AND ACCESSORY AND EXPANSION VALVE
REMOVE WATER VALVE CONTROL SERVOMOTOR
REMOVE COOL AIR BYPASS DAMPER CONTROL SERVOMOTORS
Remove the 6 screws and 2 servomotors.

Fig 1: Removing Cool Air Bypass Damper Control Servomotors
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR MIX SERVOMOTORS
Remove the 6 screws and 2 servomotors.

Fig 2: Removing Air Mix Servomotors
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR OUTLET SERVOMOTORS
1. Driver side:
  Remove the 3 screws and bracket.
2. Remove the 6 screws and 2 servomotors.
  
  Fig 3: Removing Air Outlet Servomotor (Driver Side)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 4: Removing Air Outlet Servomotor (Passenger Side)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DUCT
Remove the 5 screws and air vent duct.

Fig 5: Removing Air Vent Duct
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HEATER RADIATOR
1. Remove the screw and clamp.
2. Remove the 2 screws, 2 clamps and heater radiator pipes.
  HINT:
  
  At the time of reassembly, please refer to the following item. Do not reuse the 2 O-rings.
3. Pull out the heater radiator.
  
  Fig 6: Removing Heater Radiator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EVAPORATOR
1. Remove the 6 screws and evaporator cover.
2. Pull out the evaporator.
HINT:

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

Add 40 cc (1.4 fl.oz.)

Compressor oil: ND-OIL 8 or equivalent

Fig 7: Removing Evaporator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HEATER CASE
Remove the 5 screws, clamp and heater case.

Fig 8: Removing Heater Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002