Cooling Unit: Disassembly

WARNING: This page is about a different car, the 2002 Toyota Tundra. However, it is still accessible from the selected car via links, so may be relevant.

Remove blower resistor.
1. Remove the 2 screws and blower resistor.
Separate upper and lower unit cases.
1. Disconnect the connector clamp from upper unit case.
2. Using a knife, cut off the each packing.
3. Remove the 3 clips and 3 screws.
  
  Fig 1: Locating Screws & Clips For Removal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Separate the upper and lower unit case, then pull out the thermistor from evaporator.
Remove evaporator from lower unit case.
NOTE: At the time of reassembly, please refer to the following item:
If evaporator is replaced, add compressor oil to compressor.

Add 40 - 50 cc (1.4 -1.7 fl.oz.)

Compressor oil: ND-OIL 8 or equivalent
Remove expansion valve.
1. Using a hexagon wrench (5.0 mm, 0.20 in.), remove the 2 bolts and separate the expansion valve, evaporator and tubes.
  
  Fig 2: Removing Bolts With Hexagon Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
NOTE: At the time of reassembly, please refer to the following item:
Lubricate 4 new O-rings with compressor oil and install them to the tubes and valve.