Air Conditioning Unit: Disassembly

WARNING: This page is about a different car, the 2008 Lexus IS F. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE COOL AIR BY-PASS CONTROL SERVO MOTOR
1. Disconnect the connector
2. Remove the 3 screws and cool air by-pass control servo motor
  
  Fig 1: Locating Air Outlet Control Servo Motor RH Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR MIX CONTROL SERVO MOTOR
1. Remove the 4 clamps and connector, and disconnect the wire harness.
  
  Fig 2: Locating Air Mix Control Servo Motor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 screws and heater piping cover.
  
  Fig 3: Locating Screws And Heater Piping Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 3 screws and air mix control servo motor
  
  Fig 4: Locating Screws And Air Mix Control Servo Motor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE COOLER EXPANSION VALVE
1. Remove the packing from the air conditioning tube assembly.
  
  Fig 5: Identifying Packing From Air Conditioning Tube Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 4 mm hexagon wrench, remove the 2 hexagon bolts and air conditioning tube assembly.
3. Remove the 2 O-rings from the air conditioning tube assembly.
  
  Fig 6: Identifying O-Rings From Air Conditioning Tube Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the cooler expansion valve from the No 1 cooler evaporator sub-assembly.
  
  Fig 7: Identifying Cooler Expansion Valve From No 1 Cooler Evaporator Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR CONDITIONING HARNESS ASSEMBLY
1. Disconnect the connector.
2. Remove the air conditioning harness assembly.
  
  Fig 8: Locating Air Conditioning Harness Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR OUTLET CONTROL SERVO MOTOR
1. Remove the 2 screws and air duct.
  
  Fig 9: Locating Screws And Air Duct
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 4 screws and servo motor plate.
  
  Fig 10: Locating Screws And Servo Motor Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 screws.
4. Release the claw and remove the air outlet control servo motor from the servo motor plate.
  
  Fig 11: Locating Air Outlet Control Servo Motor From Servo Motor Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR MIX CONTROL SERVO MOTOR
1. Remove the 2 screws.
2. Release the claw and remove the air mix control servo motor from the servo motor plate.
  
  Fig 12: Locating Air Mix Control Servo Motor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY
1. Remove the screw and clamp
2. Remove the heater radiator unit sub-assembly
  
  Fig 13: Identifying Heater Radiator Unit Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
1. Remove the 5 screws
2. Release the 3 claws and remove the air duct
3. Remove the No. 1 cooler evaporator sub-assembly from the air duct.
  
  Fig 14: Identifying No. 1 Cooler Evaporator Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 2 O-rings from the No. 1 cooler evaporator sub-assembly
  
  Fig 15: Identifying Cooler Evaporator O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 COOLER THERMISTOR
1. Remove the No 1 cooler thermistor
  
  Fig 16: Identifying No 1 Cooler Thermistor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002