Air Conditioning Unit: Disassembly

WARNING: This page is about a different car, the 2007 Toyota Tacoma. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE DEFROSTER NOZZLE ASSEMBLY LOWER
1. Remove the 4 bolts and the defroster nozzle assembly lower.
  
  Fig 1: Removing Defroster Nozzle Assembly Lower With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HEATER TO REGISTER CENTER DUCT
1. Remove the 2 bolts and heater to register duct center.
  
  Fig 2: Removing Heater To Register Duct Center With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 AIR DUCT
1. Remove the bolt.
2. Disengage the 3 claws and remove the air duct.
  
  Fig 3: Removing Air Duct With Bolt & Disengaging Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR FILTER
1. Push down on the 2 tabs and open the filter door.
2. Remove the air filter.
  
  Fig 4: Removing Air Filter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MODE CONTROL SERVO MOTOR
1. Remove the 3 bolts and mode control servo motor.
  
  Fig 5: Removing Mode Control Servo Motor With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR MIX CONTROL SERVO MOTOR
1. Remove the 2 bolts and air mix control servo motor.
  
  Fig 6: Removing Air Mix Control Servo Motor With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR INLET CONTROL SERVO MOTOR
1. Remove the 2 bolts and air inlet control servo motor.
  
  Fig 7: Removing Air Inlet Control Servo Motor With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HEATER RADIATOR ASSEMBLY
1. Remove the 3 bolts and temperature mounting plate.
  
  Fig 8: Removing Temperature Mounting Plate With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the temperature cam.
  
  Fig 9: Removing Temperature Cam
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 8 bolts and heater cover case.
  
  Fig 10: Removing Heater Cover Case With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using "Torx" socket wrench T30, remove the bolt, clamp and heater radiator assembly.
  
  Fig 11: Removing Heater Radiator Assembly With Bolt & Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BLOWER RESISTOR
1. Remove the 2 bolts and blower resistor.
  
  Fig 12: Removing Blower Resistor With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BLOWER MOTOR
1. Remove the 3 bolts and blower motor.
  
  Fig 13: Removing Blower Motor With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EVAPORATOR CORE
1. Remove the 3 bolts and mode mounting plate.
  
  Fig 14: Removing Mode Mounting Plate With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the mode cam.
  
  Fig 15: Removing Mode Cam
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the bolt and heater pivot.
  
  Fig 16: Removing Heater Pivot With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Disengage the clip and remove the 11 bolts and mode case.
  
  Fig 17: Removing Mode Case With Bolts & Disengaging Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the evaporator core.
  HINT:
  
  If a new evaporator is installed, add compressor oil to the evaporator as follows.
  
  Compressor oil:
  
  RL-897 or equivalent
  
  Add 40 cc (1.4 fl.oz.)
  
  Fig 18: Removing Evaporator Core
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VALVE TO CONNECTOR TUBE
1. Using "Torx" socket wrench E10, remove the bolt and valve to connector tube.
2. Remove the 2 seal washers from the air conditioning tube assembly.
  
  Fig 19: Removing Seal Washers From Air Conditioning Tube Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXPANSION VALVE
1. Using "Torx" socket wrench T25, remove the 2 bolts and expansion valve.
2. Remove the 2 seal washers from the expansion valve.
  
  Fig 20: Removing Seal Washers From Expansion Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE COOLER THERMISTOR SENSOR
1. Disengage the 2 clamps and remove the cooler thermistor sensor.
REMOVE NO. 1 COOLER UNIT DRAIN HOSE

Fig 21: Removing Cooler Thermistor Sensor & Disengaging Clamps
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002