Air Conditioning Unit: Disassembly

WARNING: This page is about a different car, the 2005 Lexus GS 430 and 2005 Lexus GS 300. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE THESE PARTS:
1. Wire harness
2. Drain hose
REMOVE HEATER RADIATOR
1. Remove the screw and clamp.
2. Pull out the heater radiator.
REMOVE BLOWER MOTOR CONTROL RELAY
Remove the screw and blower motor control relay.
REMOVE AIR MIX SERVOMOTORS
Remove the 6 screws and both servomotors.
REMOVE AIR OUTLET SERVOMOTOR
Remove the 2 screws and servomotor.
REMOVE EXPANSION VALVE
1. Pry out the packing.
  HINT:
  
  At the time of reassembly, please refer to the following item.
  
  Do not reuse the packing.
2. Using SST, remove the 2 bolts, then separate the expansion valve, tube connector and tube and accessory.
  SST 07110-61050
  
  Torque: 4.1N.m (42 kgf.cm, 36 in.lbf)
  
  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 TEMPERATURE SENSOR
1. Disconnect the wire harness clamp.
2. Using a screwdriver, pull out the sensor with bracket plate.
  HINT:
  
  Tape the screwdriver tip before use.
3. Release the 2 claws and sensor from bracket plate.
REMOVE EVAPORATOR
1. Using SST, remove the 2 bolts and tube and accessory.
  SST 07110-61050
  
  Torque: 4.1 N.m (42 kgf.cm, 36 in.lbf)
  
  HINT:
  
  At the time of reassembly, please refer to the following item.
  
  Lubricate 2 new O-rings with compressor oil and install them to the tube.
2. Remove the 4 screws and cover.
3. Pull out the evaporator.
4. Remove the plate from evaporator.
  HINT:
  
  At the time of reassembly, please refer to the following item.
  
  If evaporator is replaced, add compressor oil to evaporator.
  
  Add 40 cc (1.4 fl.oz.)
  
  Compressor oil: ND-OIL 8 or equivalent
REMOVE INSULATOR FROM HEATER CASE
REMOVE AIR DUCT
Remove the 4 screws and duct.