Air Conditioning Unit: Disassembly

REMOVE HEATER TO REGISTER DUCT CENTER
1. Release the 4 claws and remove the heater to register duct center.
  
  Fig 1: Identifying Heater To Register Duct Center
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR OUTLET CONTROL SERVO MOTOR
1. Remove the 3 screws and air outlet control servomotor.
  
  Fig 2: Identifying Air Outlet Control Servo Motor
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REMOVE AIR MIX CONTROL SERVO MOTOR
1. LH side:
  Remove the 3 screws and air mix control servomotor.
  
  Fig 3: Identifying Air Mix Control Servo Motor (LH Side)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. RH side:
  Remove the 3 screws and air mix control servomotor.
  
  Fig 4: Identifying Air Mix Control Servo Motor (RH Side)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EVAPORATOR TEMPERATURE SENSOR
1. Release the clamp and connector.
2. Release the 2 claws and remove evaporator temperature sensor.
  
  Fig 5: Identifying Evaporator Temperature Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY
1. Remove the 2 screws and piping cover.
  
  Fig 6: Identifying Piping Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the screw and bracket.
  
  Fig 7: Identifying Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the heater radiator unit sub-assembly.
  NOTE: Prepare a drain pan or cloth for cooling water leaks.
  
  Fig 8: Identifying Heater Radiator Unit Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR CONDITIONING TUBE ASSEMBLY
1. Remove the packing.
  
  Fig 9: Identifying Air Conditioning Tube Assembly Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a hexagon wrench 4.0 mm, remove the 2 hexagon bolts and air conditioning tube assembly.
3. Remove the 2 O-rings from the air conditioning tube assembly.
  
  Fig 10: Identifying Air Conditioning Tube Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE COOLER EXPANSION VALVE
1. Remove the cooler expansion valve from the cooler evaporator sub-assembly No.1.
  
  Fig 11: Identifying Cooler Expansion Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE COOLER EVAPORATOR NO.1 SUB-ASSEMBLY
1. Remove the 3 screws and air duct sub-assembly.
  
  Fig 12: Identifying Air Duct Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Release the 4 claws and remove the air duct sub-assembly.
  
  Fig 13: Identifying Air Duct Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 11 screws and separate the heater case.
4. Remove the cooler evaporator No.1 sub-assembly.
  
  Fig 14: Separating Heater Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the 2 O-rings from the cooler evaporator No.1 sub-assembly.
  
  Fig 15: Identifying 2 O-Rings From Cooler Evaporator No.1 Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002