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Air Conditioning Unit: Disassembly

  1. REMOVE DEFROSTER DAMPER CONTROL CABLE SUB-ASSEMBLY 
    1. Using a screwdriver with its tip wrapped in protective tape, disengage the claw and remove the defroster damper control cable.
      Fig 1: Removing Defroster Damper Control Cable
      G05401696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE AIR MIX DAMPER CONTROL CABLE SUB-ASSEMBLY 
    1. Using a screwdriver with its tip wrapped in protective tape, disengage the claw and remove the air mix damper control cable.
      Fig 2: Removing Air Mix Damper Control Cable
      G05401697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE NO. 1 AIR DUCT 
    1. Disengage the 3 claws and remove the air duct.
      Fig 3: Identifying No 1 Air Duct Claws
      G05401698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE NO. 2 AIR DUCT 
    1. Disengage the 3 claws and remove the air duct.
      Fig 4: Identifying No 2 Air Duct Claws
      G05401699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE PTC HEATER ASSEMBLY 
    1. Disengage the clamp.
    2. Remove the 2 screws and PTC heater from the air conditioning unit.
      Fig 5: Locating PTC Heater Assembly Screws
      G05401700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY 
    1. Disengage the 3 claws and remove the clamp.
      Fig 6: Identifying Claws
      G05401701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the heater radiator unit from the air conditioning unit.
      Fig 7: Removing Heater Radiator Unit From Air Conditioning Unit
      G05401702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE COOLER EXPANSION VALVE 
    1. Using a 4 mm hexagon wrench, remove the 2 hexagon bolts and detach the cooler expansion valve.
      2. Fig 8: Identifying Cooler Expansion Valve Bolts
      G05401703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 O-rings from the cooler evaporator.
  8. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY 
    1. Disengage the evaporator temperature sensor connector clamp.
      Fig 9: Identifying Evaporator Temperature Sensor Connector Clamp
      G05401704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 screws.
    3. Disengage the 4 claws and remove the heater case lower.
      Fig 10: Identifying Heater Case Lower Claws
      G05401705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the cooler evaporator.
      Fig 11: Identifying Cooler Evaporator
      G05401706Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE DRAIN COOLER HOSE 
    1. Remove the drain cooler hose.
      2. Fig 12: Locating Drain Cooler Hose
      G05401707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE FRONT EVAPORATOR TEMPERATURE SENSOR  (See REMOVAL  )
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