Rear Cooling Unit: Disassembly

WARNING: This page is about a different car, the 2006 Toyota Land Cruiser. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE AIR CONDITIONING AMPLIFIER
1. Remove the 2 screws and amplifier.
  
  Fig 1: Removing Air Conditioning Amplifier Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE POWER TRANSISTOR
1. Disconnect the connector.
2. Remove the 2 screws and power transistor.
  
  Fig 2: Removing Power Transistor Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE COOLING UNIT CASE
1. Remove the wire harness.
2. Remove the 11 screws, 3 holding springs and separate the cooling unit cases.
3. Disconnect the connector.
4. Remove the blower case.
  
  Fig 3: Removing Cooling Unit Case Screws & Holding Springs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BLOWER MOTOR
1. Remove the 3 screws and blower motor.
  
  Fig 4: Removing Blower Motor Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EVAPORATOR
1. Disconnect the 2 connector clamps.
2. Remove the 10 screws and 2 holding springs, and separate the cooling unit cases.
  
  Fig 5: Removing Screws & Holding Springs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the screw and piping clamp.
4. Loosen the 2 nuts and remove the tube and accessory.
  Torque: Liquid line
  
  14 N*m (140 kgf*cm, 10 ft.*lbf)
  
  Suction line
  
  32 N*m (330 kgf*cm, 24 ft.*lbf)
  
  Fig 6: Removing Tube & Accessory
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
  
  HINT:
  
  At the time of reassembly, lubricate 2 new O-rings with compressor oil and install them in the tubes.
5. Remove the evaporator.
  HINT:
  
  At the time of reassembly, if evaporator was replaced, add compressor oil to the new evaporator.
  
  Add oil amount: 40 cc (1.4 fl.oz.)
  
  Compressor oil: ND-OIL 8 or equivalent
  
  Fig 7: Removing Evaporator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE COOLER THERMISTOR
1. Remove the cooler thermistor from evaporator.
  
  Fig 8: Removing Cooler Thermistor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXPANSION VALVE

Fig 9: Removing Expansion Valve
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a 5 mm hexagon wrench, remove the 2 hexagon bolts and separate the expansion valve and evaporator.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  
  HINT:
  
  At the time of reassembly, lubricate 4 new O-rings with compressor oil and install them in the tubes.