Air Conditioning Unit: Disassembly

WARNING: This page is about a different car, the 2008 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE NO. 3 HEATER TO REGISTER DUCT
1. Detach the 6 claws and remove the heater to register duct.
  
  Fig 1: Identifying Heater To Register Duct And Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR DUCT
1. Detach the 2 claws and remove the air duct.
  
  Fig 2: Identifying Air Duct And Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR OUTLET CONTROL SERVO MOTOR
1. Remove the 3 screws.
2. Detach the evaporator case from the blower case.
  
  Fig 3: Identifying Evaporator Case From Blower Case And Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 3 screws and disconnect the connector.
4. Remove the air outlet control servo motor.
  
  Fig 4: Identifying Screws And Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR MIX CONTROL SERVO MOTOR
1. Remove the 3 screws and disconnect the connector.
2. Remove the air mix control servo motor.
  
  Fig 5: Identifying Air Mix Control Servo Motor Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MODE CONTROL CABLE ASSEMBLY (for Manual Air Conditioning System)
1. Remove the 3 screws.
2. Detach the evaporator case from the blower case.
  
  Fig 6: Identifying Evaporator Case From Blower Case And Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Detach the 3 claws and remove the cable.
  
  Fig 7: Installing Mode Control Cable Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REPAIR AIRMIX DAMPER CONTROL CABLE SUB-ASSEMBLY (for Manual Air Conditioning System)
1. Detach the 3 claws and remove the cable.
  
  Fig 8: Installing Airmix Damper Control Cable
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY
1. Detach the screw and remove the clamp.
2. Remove the heater radiator unit.
  
  Fig 9: Identifying Heater Radiator Unit Sub-Assembly Screw And Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE COOLER EXPANSION VALVE
1. Using a 4 mm hexagon wrench, remove the 2 hexagon bolts.
2. Remove the cooler expansion valve and 2 O-rings from the cooler evaporator.
  
  Fig 10: Identifying Cooler Expansion Valve And O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
1. Remove the 4 screws.
2. Detach the 2 claws and remove the cover.
  
  Fig 11: Locating Screws And Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Detach the cooler thermistor clamp.
4. Remove the cooler thermistor and cooler evaporator from the case.
  
  Fig 12: Identifying Cooler Thermistor Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EVAPORATOR TEMPERATURE SENSOR
1. Disconnect the cooler thermistor clamp from the cooler evaporator.