Air Conditioning Unit: Disassembly

REMOVE AIR FILTER CASE
1. Release the 2 fitting claws and remove the air filter case.
  
  Fig 1: Identifying Air Filter Case And Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CLEAN AIR FILTER
1. Remove the air filter from the air conditioning unit assembly.
  HINT:
  
  Removing only the glove compartment door assembly makes it possible to install the air filter.
  
  Fig 2: Removing Air Filter From Air Conditioning Unit Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DAMPER SERVO SUB-ASSEMBLY
1. Remove the 2 screws and damper servo sub-assembly.
  HINT:
  
  Removing only instrument panel sub-assembly upper and heater to register duct No. 1 makes it possible to install the damper servo sub-assembly.
  
  Fig 3: Locating Damper Servo Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BLOWER W/FAN MOTOR SUB-ASSEMBLY
1. Remove the 3 screws and blower w/fan motor sub-assembly.
  HINT:
  
  Removing only the ECM makes it possible to install the blower w/fan motor sub-assembly.
  
  Fig 4: Locating Blower W/Fan Motor Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BLOWER RESISTOR
1. Disconnect the connector.
2. Remove the 2 screws and blower resistor.
  HINT:
  
  Removing only the ECM makes it possible to install the blower resistor.
  
  Fig 5: Locating Blower Resistor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HEATER PIPING COVER
1. Release the 3 fitting claws and remove the heater piping cover.
  
  Fig 6: Identifying Heater Piping Cover And Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY
1. Release the 3 fitting claws and remove the heater piping clamp and heater radiator unit sub-assembly.
  
  Fig 7: Identifying Heater Piping Clamp And Heater Radiator Unit Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE COOLER THERMISTOR NO. 1
1. Remove the clamp.
2. Release the fitting claw and remove the 2 screws and heater case.
  
  Fig 8: Identifying Clamp And Heater Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 9: Identifying Heater Case And Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Release the fitting claw and remove the 5 screws and heater case.
  
  Fig 10: Locating Heater Case And Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the cooler thermistor No. 1 from the cooler evaporator sub-assembly No. 1.
  
  Fig 11: Identifying Cooler Thermistor No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR CONDITIONING TUBE ASSEMBLY
1. Remove the cooler evaporator assembly from the heater case.
2. Remove the packing.
  
  Fig 12: Identifying Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a hexagon wrench 5.0 mm (0.20 in.), remove the 2 hexagon bolts and air conditioning tube assembly.
4. Remove the 2 O-rings from the air conditioning tube assembly.
  
  Fig 13: Identifying Air Conditioning Tube Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE COOLER EXPANSION VALVE
1. Remove the cooler expansion valve from the cooler evaporator sub-assembly No. 1.
2. Remove the 2 O-rings from the cooler evaporator sub-assembly No. 1.
  HINT:
  
  Removing only instrument panel sub-assembly upper, heater to register duct No. 1 and heater case makes it possible to install the cooler expansion valve.
  
  Fig 14: Identifying Cooler Expansion Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE COOLER EVAPORATOR SUB-ASSEMBLY NO. 1
REMOVE COOLER UNIT DRAIN HOSE NO. 1