Front Cooling Unit: Disassembly

WARNING: This page is about a different car, the 2005 Toyota Land Cruiser. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE EVAPORATOR
1. Disconnect the connector clamp.
2. Remove the 8 screws and No. 1 cooler cover.
3. Pull out the evaporator
  HINT:
  
  At the time of reassembly, if evaporator is replaced, add compressor oil to the evaporator.
  - Add: 40 cc (1.4 fl.oz.)
  - Compressor oil: ND-OIL 8 or equivalent
  Fig 1: Removing Evaporator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
PULL OUT EVAPORATOR TEMPERATURE SENSOR FROM EVAPORATOR

Fig 2: Pulling Out Evaporator Temperature Sensor From Evaporator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXPANSION VALVE
1. Remove the grommet.
  
  Fig 3: Removing Grommet
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Pry out the packing.
  HINT:
  
  At the time of reassembly, do not reuse the packing.
3. Using a hexagon wrench (5.0 mm, 0.20 in.), remove the 2 bolts and separate the expansion valve, tube and evaporator.
  Torque: 3.4 N.m (35 kgf.cm, 30 in.lbf)
  
  NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system.
  
  HINT:
  
  At the time of reassembly, lubricate 4 new O-rings with compressor oil and install them in the tube.
REMOVE DRAIN HOSE