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Air Conditioning Unit: Disassembly

WARNING: This page is about a different car, the 2006 Lexus IS 350 and 2006 Lexus IS 250. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE AIR OUTLET CONTROL SERVO MOTOR 
    1. Disconnect the connector.
    2. Remove the 3 screws and air outlet control servo motor.
    Fig 1: Identifying Screws And Air Outlet Control Servo Motor
    G04048403Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE AIR MIX CONTROL SERVO MOTOR 
    1. Remove the 4 clamps and connector, and disconnect the wire harness.
      Fig 2: Identifying Wire Harness Connector
      G04048404Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 screws and heater piping cover.
      Fig 3: Identifying Screws And Heater Piping Cover
      G04048405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 3 screws and air mix control servo motor.
    Fig 4: Identifying Screws And Air Mix Control Servo Motor
    G04048406Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE COOLER EXPANSION VALVE 
    1. Remove the packing from the air conditioning tube assembly.
      Fig 5: Identifying Packing For Air Conditioning Tube Assembly
      G04048407Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a hexagon wrench 4 mm, remove the 2 hexagon bolts and air conditioning tube assembly.
    3. Remove the 2 O-rings from the air conditioning tube assembly.
      Fig 6: Identifying O-Rings For Air Conditioning Tube Assembly
      G04048408Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the cooler expansion valve from the No. 1 cooler evaporator sub-assembly.
    Fig 7: Identifying Cooler Expansion Valve
    G04048409Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE AIR CONDITIONING HARNESS ASSEMBLY 
    1. Remove the 2 connectors and 5 clamps, and then disconnect the wire harness.
    2. Remove the air conditioning harness assembly as shown in the illustration.
    Fig 8: Identifying Wire Harness Connector
    G04048410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE AIR OUTLET CONTROL SERVO MOTOR 
    1. Remove the 2 screws and the air duct.
      Fig 9: Identifying Air Outlet Control Servo Motor
      G04048411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 screws and the servo motor plate.
      Fig 10: Identifying Screws And Servo Motor Plate
      G04048412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 screws.
    4. Release the claw and remove the air outlet control servo motor from the servo motor plate.
    Fig 11: Identifying Air Outlet Control Servo Motor
    G04048413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE AIR MIX CONTROL SERVO MOTOR 
    1. Remove the 2 screws.
    2. Release the claw and remove the air mix control servo motor from the servo motor plate.
    Fig 12: Identifying Air Mix Control Servo Motor And Servo Motor Plate
    G04048414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY 
    1. Remove the screw and clamp.
    2. Remove the heater radiator unit sub-assembly.
    Fig 13: Identifying Heater Radiator Unit Sub-Assembly
    G04048415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE NO. 1 COOLER EVAPORATOR SUBASSEMBLY 
    1. Remove the 5 screws.
    2. Release the 3 claws and remove the air duct.
      Fig 14: Identifying Air Duct
      G04048416Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the No. 1 cooler evaporator sub-assembly from the air duct.
    4. Remove the 2 O-rings from the No. 1 cooler evaporator sub-assembly.
    Fig 15: Identifying O-Rings For No. 1 Cooler Evaporator Sub-Assembly
    G04048417Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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