Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSTOYOTA2004CELICA GT, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 42 (MANUAL A/C-HEATER SYSTEMS)COOLING UNITDISASSEMBLY

2004 Toyota Celica GT, Standard

Cooling Unit: Disassembly

2004 Toyota Celica GT, StandardSECTION Disassembly

WARNING: This page is about a different car, the 2002 Toyota Tundra. However, it is still accessible from the selected car via links, so may be relevant.

Remove blower resistor.
1. Remove the 2 screws and blower resistor.
Separate upper and lower unit cases.
1. Disconnect the connector clamp from upper unit case.
2. Using a knife, cut off the each packing.
3. Remove the 3 clips and 3 screws.
  
  Fig 1: Locating Screws & Clips For Removal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Separate the upper and lower unit case, then pull out the thermistor from evaporator.
Remove evaporator from lower unit case.
NOTE: At the time of reassembly, please refer to the following item:
If evaporator is replaced, add compressor oil to compressor.

Add 40 - 50 cc (1.4 -1.7 fl.oz.)

Compressor oil: ND-OIL 8 or equivalent
Remove expansion valve.
1. Using a hexagon wrench (5.0 mm, 0.20 in.), remove the 2 bolts and separate the expansion valve, evaporator and tubes.
  
  Fig 2: Removing Bolts With Hexagon Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
NOTE: At the time of reassembly, please refer to the following item:
Lubricate 4 new O-rings with compressor oil and install them to the tubes and valve.

RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.
• Brakes feel soft, pull hard to one side, or make grinding noises.
• The engine overheats, stalls repeatedly, or misfires under load.
• You are missing required tools, torque specs, or safe lifting equipment.
• You are not confident in the next step or safety outcome.