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Rear A/C Unit: Disassembly

WARNING: This page is about a different car, the 2002 Toyota Sequoia. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove blower motor  .
  2. Remove power transistor  .
  3. Remove thermistor  .
  4. Remove water valve  .
    1. Remove the packing.
    2. Remove the 3 screws and 2 brackets. See Fig 1.
      Fig 1: Locating Water Valve Bracket Screws
      G01127828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Grip the claws of the hose clips and slide the hose clips along the hoses. See Fig 2.
    4. Disconnect the water hoses and pipes.
      Fig 2: Locating Water Valve Hose Clips
      G01127829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 2 screws and 2 clamps. See Fig 3.
    6. Remove the 3 screws and water valve.
  5. Remove drain hose  .
    Fig 3: Locating Water Valve & Clamp Screws
    G01127830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Remove expansion valve  :
    1. Remove the 4 screws and 2 brackets. See Fig 4.
      2. NOTE:

      At the time of installation, please refer to the following item. Do not refuse the packing.

    2. Pry out the packings.
      3. CAUTION: Cap the open fittings immediately to keep moisture or dirt out of the system.
      NOTE:

      At the time of installation, please refer to the following item. Lubricate 2 new O-rings with compressor oil and install them to the tube and valve.

      Fig 4: Locating Expansion Valve, Brackets & Screws
      G01127831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a hexagon wrench (5.0mm, 0.20 in.), remove the 2 bolts and expansion valve.

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

    4. Remove the holder and disconnect the heat sensing tube. See Fig 5.
      5. NOTE: At the time of installation, please refer to the following item. Lubricate 2 new O-rings with compressor oil and install them to the expansion valve.
    5. Loose the 2 nuts and remove the expansion valve.

      Torque: 

      Nut A: 13 N.m (135 kgf.cm, 10 ft.lbf) 

      Nut B: 22 N.m (235 kgf.cm, 16 ft.lbf) 

    Fig 5: Removing Heat Sensing Tube
    G01127832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. Remove evaporator  :
    1. Remove the 8 screws and cover. See Fig 6.
    2. Pull out the evaporator.
    Fig 6: Removing Evaporator
    G01127833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. Remove air outlet servomotor  :
      NOTE: Tape the screwdriver tip before use.
    1. Using a screwdriver, release the claw and remove the plate.
    2. Remove the 3 screws and servomotor. See Fig 7.
    Fig 7: Locating Servomotor
    G01127834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. Separate rear A/C unit  :
    1. Remove the 2 screws, clamp and blower case. See Fig 8.
    2. Remove the 10 screws and separate the A/C unit.
    3. Remove the sliding door and shaft.
    4. Remove the heater radiator and insulator.
    Fig 8: Removing Rear A/C Unit
    G01127835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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