AIR CONDITIONING UNIT (for Sedan): Disassembly

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

REMOVE DEFROSTER DAMPER CONTROL CABLE SUB-ASSEMBLY
1. Using a screwdriver with its tip wrapped in protective tape, disengage the claw and remove the defroster damper control cable.
  
  Fig 1: Removing Defroster Damper Control Cable
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR MIX DAMPER CONTROL CABLE SUB-ASSEMBLY
1. Using a screwdriver with its tip wrapped in protective tape, disengage the claw and remove the air mix damper control cable.
  
  Fig 2: Removing Air Mix Damper Control Cable
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 AIR DUCT
1. Disengage the 3 claws and remove the air duct.
  
  Fig 3: Identifying Claws For Air Duct
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 AIR DUCT
1. Disengage the 3 claws and remove the air duct.
  
  Fig 4: Identifying Claws For No. 2 Air Duct
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY
1. Disengage the 3 claws and remove the clamp.
  
  Fig 5: Locating Claws And Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the heater radiator unit from the air conditioner radiator assembly.
  
  Fig 6: Removing Heater Radiator Unit
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE COOLER EXPANSION VALVE
1. Using a hexagon wrench 4, remove the 2 hexagon bolts and detach the cooler expansion valve.
2. Remove the 2 O-rings from the No. 1 cooler evaporator.
  
  Fig 7: Removing Hexagon Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
1. Disengage the cooler thermistor connector.
  
  Fig 8: Identifying Cooler Thermistor Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 screws.
3. Disengage the 4 claws and remove the heater case lower.
  
  Fig 9: Identifying Claws For Heater Case Lower
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the cooler evaporator.
  
  Fig 10: Identifying Cooler Evaporator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 COOLER THERMISTOR
1. Remove the cooler thermistor from the cooler evaporator.
  
  Fig 11: Removing No. 1 Cooler Thermistor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002