Rear Cooling Unit: Disassembly

REMOVE AIR REFINER FILTER
REMOVE BLOWER SPEED CONTROL
REMOVE REAR DAMPER SERVOMOTOR
REMOVE BLOWER RESISTOR
REMOVE DRAIN HOSE
REMOVE COOLING BOX
1. W/Cool box models:
  Remove the 3 screws, clip and 2 ducts.
2. Disconnect the connector.
3. Remove the screw and cooling box light.
4. Remove the cooling box.
  
  Fig 1: Removing Cooling Box
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SMOKE SENSOR
1. Disconnect the connector.
2. Remove the 4 screws and smoke sensor.
  
  Fig 2: Removing Smoke Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR DUCT
Remove the 3 screws and duct.

Fig 3: Removing Air Duct
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BLOWER MOTOR
1. Remove the 4 screws and filter case.
2. Disconnect the connector.
  
  Fig 4: Removing Filter Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 3 screws and blower motor.
  
  Fig 5: Removing Blower Motor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the nut and fan.
REMOVE WIRE HARNESS

Fig 6: Removing Nut & Fan
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EVAPORATOR
1. Remove the 4 screws and cooler case.
2. Remove the evaporator.
HINT:

At the time of reassembly, please refer to the following item. If evaporator is replaced, add compressor oil to the evaporator.

ADD: 40 cc (1.4 fl.oz.)

Compressor Oil; ND-OIL 8 or equivalent

Fig 7: Removing Evaporator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXPANSION VALVE W/ MAGNETIC VALVE
Using a hexagon wrench (5.0 mm, 0.20 in.), remove the 2 bolts, tube and expansion valve.

Torque: 3.5 N.m (36 kgf.cm, 31 in.lbf)

NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system.

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 tube.

Fig 8: Removing Expansion Valve (With Magnetic Valve)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002