Air Conditioning Unit: Disassembly

WARNING: This page is about a different car, the 2004 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE THERMISTOR
1. Disconnect the connector clamp.
2. Release the 4 claws and remove the harness from the plate.
3. Using a screwdriver, pull out the thermistor from the A/C unit case.
  
  Fig 1: Pulling Out Thermistor From A/C Unit Case Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Tape the screwdriver tip before use.
4. Release the 2 claws and remove the thermistor from the bracket plate.
  
  Fig 2: Removing Thermistor From Bracket Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EVAPORATOR
1. Remove the 7 screws.
2. Pull out the evaporator from the A/C unit case.
3. Remove the packing.
  
  Fig 3: Removing 7 Screws & Evaporator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXPANSION VALVE
1. Remove the evaporator cover.
2. Using a 5 mm hexagon wrench, remove the 2 bolts, and separate the expansion valve and evaporator.
  
  Fig 4: Removing 2 Bolts Using 5 MM Hexagon Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HEATER RADIATOR
1. Remove the 4 screws and 3 clamps.
2. Remove the passenger air duct subassembly.
3. Pull out the heater radiator from the A/C unit case.
  
  Fig 5: Removing 4 Screws, 3 Clamps & Heater Radiator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002