Air Conditioning Unit: Disassembly

REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY
1. Release the 2 claws and remove the No. 2 air duct sub-assembly as shown in the illustration.
  
  Fig 1: Removing No. 2 Air Duct Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BLOWER ASSEMBLY
1. Disconnect the connector.
2. Remove the 2 screws and blower assembly.
  
  Fig 2: Identifying Blower Assembly Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 6 HEATER TO REGISTER DUCT ASSEMBLY
1. Release the 4 claws and remove the No. 6 heater to register duct assembly.
  
  Fig 3: Identifying No. 6 Heater To Register Duct Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DRAIN COOLER HOSE
1. Remove the drain cooler hose from the air conditioning radiator assembly.
  
  Fig 4: Identifying Drain Cooler Hose From Air Conditioning Radiator Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR OUTLET CONTROL SERVO MOTOR
1. Disconnect the 2 connectors and remove the air conditioner harness.
2. Remove the 3 screws and then remove the air outlet control servo motor.
  
  Fig 5: Locating Air Outlet Control Servo Motor Connectors And Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR MIX CONTROL SERVO MOTOR
1. Remove the 2 screws and air mix control servo motor.
  
  Fig 6: Identifying Screws And Air Mix Control Servo Motor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY
1. Remove the screw and clamp.
2. Release the 4 claws and remove the clamp.
  
  Fig 7: Identifying Heater Radiator Unit Sub-Assembly Claws, Screw And Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the heater radiator unit sub-assembly from the air conditioning radiator assembly.
  NOTE: Prepare a drain pan or cloth in case the cooling water leaks.
  
  Fig 8: Identifying Heater Radiator Unit Sub-Assembly From Air Conditioning Radiator Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE COOLER EXPANSION VALVE
1. Using a 4 mm hexagon wrench, remove the 2 hexagon bolts and cooler expansion valve.
  
  Fig 9: Identifying Cooler Expansion Valve And Hexagon Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
1. Remove the 6 screws, release the 5 claws, and remove the plate cover.
  
  Fig 10: Locating No. 1 Cooler Evaporator Sub-Assembly Screws And Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the clamp and No. 1 cooler thermistor.
  
  Fig 11: Identifying Clamp And No. 1 Cooler Thermistor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the No. 1 cooler evaporator sub-assembly.
  
  Fig 12: Identifying Cooler Evaporator Sub-Assembly No.1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 2 O-rings from the No. 1 cooler evaporator sub-assembly.
  
  Fig 13: Identifying O-Rings From Cooler Evaporator Sub-Assembly No.1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002