Air Conditioning Unit: Disassembly

WARNING: This page is about a different car, the 2002 Lexus RX 300. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE AIR OUTLET SERVOMOTOR
1. Disconnect the connector.
2. Remove the 2 screws and servomotor.
  
  Fig 1: Removing Air Outlet Servomotor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WIRE HARNESS
REMOVE BRACKET
Remove the bolt and bracket.

Fig 2: Removing Bolt And Bracket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HEATER RADIATOR
1. Remove the 2 screws and 2 plates.
2. Pull out the heater radiator.
  
  Fig 3: Removing Heater Radiator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BLOWER MOTOR CONTROL RELAY
Remove the screw and blower motor control relay.

Fig 4: Removing Blower Motor Control Relay
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR MIX SERVOMOTOR
Remove the 2 screws and servomotor.

Fig 5: Removing Air Mix Servomotor
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Release the 2 claws and remove the sensor from bracket plate.
  
  Fig 7: Removing Evaporator Temperature Sensor From Bracket Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
  Fig 8: Removing Expansion Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
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.
  
  Fig 10: Removing Tube And Accessory
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Lubricate 2 new O-rings with compressor oil and install them to the tube.
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.
  
  Add 40 cc (1.4fl.oz.)
  
  Compressor oil: ND-OIL 8 or equivalent
4. Remove the insulator.
  
  Fig 11: Removing Evaporator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002