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Air Conditioning Unit: Disassembly

WARNING: This page is about a different car, the 2008 Toyota Tundra. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE LOWER DEFROSTER NOZZLE ASSEMBLY 
    1. Detach the 4 claws and remove the nozzle.
      Fig 1: Identifying Lower Defroster Nozzle Assembly Claws
      G05155523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY 
    1. Detach the 4 claws and remove the duct.
      Fig 2: Identifying No. 3 Air Duct Sub-Assembly Claws
      G05155524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE AIR FILTER COVER PLATE 
    1. Detach the 2 clips and remove the plate.
      Fig 3: Identifying Air Filter Cover Plate Clips
      G05155525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE CLEAN AIR FILTER 
    1. Remove the filter.
      Fig 4: Locating Clean Air Filter
      G05155526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY 
    1. Remove the screw and duct.
      Fig 5: Identifying No. 2 Air Duct Sub-Assembly Screw
      G05155527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY 
    1. Remove the 2 screws and amplifier.
      Fig 6: Identifying Air Conditioning Amplifier Assembly Screws
      G05155528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE BLOWER WITH FAN MOTOR SUB-ASSEMBLY 
    1. Remove the 3 screws and motor.
      Fig 7: Locating Blower With Fan Motor Sub-Assembly Screws
      G05155529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE AIR DUCT 
    1. Remove the 2 screws and duct.
      Fig 8: Locating Air Duct Screws
      G05155530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE DAMPER SERVO SUB-ASSEMBLY 
    1. Disconnect the 2 connectors.
    2. Remove the 4 screws and damper servo.
      Fig 9: Locating Damper Servo Screws
      G05155531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the servo motor.
      1. Detach the claw and remove the main plate.
      2. Remove the 2 screws and damper servo.
        Fig 10: Locating Screws And Damper Servo
        G05155532Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the servo motor.
      1. Detach the claw and remove the main plate.
      2. Remove the 2 screws and damper servo.
        Fig 11: Locating Claw And Main Plate
        G05155533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE DAMPER SERVO SUB-ASSEMBLY 
    1. Disconnect the connector.
    2. Remove the 3 screws and damper servo.
      Fig 12: Identifying Damper Servo Screws
      G05155534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE BLOWER CASE SUB-ASSEMBLY 
    1. Remove the 3 screws.
    2. Detach the 2 claws and remove the case.
      Fig 13: Identifying Blower Case Claws And Screws
      G05155535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE BLOWER DAMPER SERVO SUB-ASSEMBLY 
    1. Disconnect the connector.
    2. Remove the 3 screws and damper servo.
      Fig 14: Locating Damper Servo Screws And Connector
      G05155536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE COOLING UNIT DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System) 
    1. Disconnect the connector.
    2. Remove the 3 screws and damper servo.
      Fig 15: Identifying Damper Servo Screws And Connector
      G05155537Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY 
    1. Remove the 3 screws and plate.
      Fig 16: Identifying Heater Radiator Unit Plate And Screws
      G05155538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the 3 claws and remove the heater clamp.
    3. Remove the heater radiator unit.
      Fig 17: Identifying Heater Clamp Claws
      G05155539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY 
    1. Remove the packing.
      Fig 18: Identifying No. 1 Cooler Evaporator Packing
      G05155540Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 6 screws and detach the 4 claws.
    3. Remove the blower case (back side).
      Fig 19: Locating Blower Case Screws And Claws
      G05155541Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the evaporator from the blower case (front side).
      Fig 20: Identifying Evaporator
      G05155542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE EVAPORATOR TEMPERATURE SENSOR 
    1. Remove the sensor.
      Fig 21: Identifying Evaporator Temperature Sensor
      G05155543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE COOLER EXPANSION VALVE 
    1. Using a 4 mm hexagon wrench, remove the 2 bolts.
    2. Remove the tube and accessory and 2 O-rings.
    3. Remove the cooler expansion valve and 2 O-rings from the cooler evaporator.
      Fig 22: Identifying Cooler Expansion Valve Bolts
      G05155544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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