Rear Cooling Unit: Disassembly

WARNING: This page is about a different car, the 2003 Lexus LX 470. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE A/C AMPLIFIER
Remove the 2 screws and the A/C amplifier.

Fig 1: Removing A/C Amplifier Screws
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REMOVE POWER TRANSISTOR
1. Disconnect the connector.
2. Remove the 2 screws and the power transistor.
  
  Fig 2: Removing Power Transistor Screws<
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BLOWER CASE
1. Remove the wire harness.
2. Remove the 11 screws, 3 holding springs and separate the cooling unit cases.
3. Disconnect the connector.
4. Remove the blower case.
  
  Fig 3: Removing Blower Case Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BLOWER MOTOR
Remove the 3 screws and the blower motor.

Fig 4: Removing Blower Motor
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REMOVE EVAPORATOR
1. Disconnect the 2 connector clamps.
2. Remove the 10 screws and the 2 holding springs, and separate the cooling unit cases.
  
  Fig 5: Separating Cooling Unit Cases
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Pull out the thermistor from the evaporator.
  
  Fig 6: Pulling Out Thermistor From Evaporator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the screw and the piping clamp.
5. Loosen the 2 nuts and remove the tube and accessory.
  Torque:
  
  Liquid line: 14 N.m (140 kgf.cm, 10 ft.lbf)
  
  Suction line: 32 N.m (330 kgf.cm, 24 ft.lbf)
  
  NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system.
  
  HINT:
  
  At the time of reassembly, lubricate 2 new O-rings with compressor oil and install them in the tubes.
6. Remove the evaporator.
  HINT:
  
  At the time of reassembly, if evaporator was replaced, add compressor oil to the new evaporator.
  
  Add 40 cc:(1.4fl.oz.)
  
  Compressor oil: ND-OIL 8 or equivalent
  
  Fig 8: Removing Evaporator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXPANSION VALVE
Using a hexagon wrench (5.0 mm, 0.20 in.), remove the 2 bolts and separate the expansion valve and evaporator.

Torque: 5.4 N.m(55 kgf.cm, 48 in.lbf)

HINT:

At the time of reassembly, lubricate 4 new O-rings with compressor oil and install them in the tubes.

Fig 9: Removing Expansion Valve
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002