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HOMESERVICE MANUALSTOYOTA2004MATRIX XR, FWD, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 400 (2002 AIR CONDITIONING)AIR CONDITIONING UNITDISASSEMBLY
2004 Toyota Matrix XR, FWD, Standard

Air Conditioning Unit: Disassembly

2004 Toyota Matrix XR, FWD, StandardSECTION Disassembly
WARNING: This page is about a different car, the 2002 Lexus IS 300. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove Wire Harness 
  2. Remove Drain Hose 
  3. Remove Heater Radiator 
      Fig 1: Removing Heater Radiator
      G01178951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the screw and clamp.
    2. Pull out the heater radiator.
  4. Remove Blower Motor Control Relay 

    Remove the screw and blower motor control relay.

  5. Remove Air Mix Servomotor 

    Remove the 3 screws and servomotor.

  6. Remove Air Outlet Servomotor 

    Remove the 2 screws and servomotor.

  7. Remove Expansion Valve 
    1. Pry out the packing.

      HINT:

      At the time of reassembly, please refer to the following item. Do not reuse the packing.

    2. Using SST, remove the 2 bolts, then separate the expansion valve, and tube connector.

      SST 07110-61050

      Torque: 4.1 N.m (42 kgf.cm, 36 in.lbf) 

    HINT:

    At the time of reassembly, please refer to the following item. Lubricate 4 new O-rings with compressor oil and install them to the valve.

  8. Remove Evaporator Temperature Sensor 
    1. Using a screwdriver, pull out the sensor with bracket plate.

      HINT:

      Tape the screwdriver tip before use.

    2. Release the 2 claws and sensor from bracket plate.
  9. Remove Evaporator 
    1. Remove air mix servomotor.
      1. Disconnect the connector.
        Fig 2: Removing Evaporator From A/C System
        G01178952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Remove the 3 screws and servomotor.
    2. Remove tube and accessory.
      1. Pry out packing.

        HINT:

        At the time of installation, please refer to the following item. Do not reuse the packing.

      2. Using SST, remove the 2 bolts and the tube and accessory.
        Fig 3: Using SST To Remove 2 Bolts, Tube & Accessories
        G01178953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        1. SST 07110-61050
        2. Torque: 4.1 N.m (42 kgf.cm, 36 in.lbf) 
        NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system.
        1. HINT:
        2. At the time of installation, please refer to the following item. Lubricate 2 new O-rings with compressor oil and install them to the tube.
      3. Remove screw and drain pipe.
    3. Remove evaporator.
      Fig 4: Removing Evaporator From A/C System
      G01178954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the screw and drain hose.
      2. Remove the 4 screws and cover.
      3. Pull out the evaporator.
      1. HINT:
      2. At the time of installation, please refer to the following item. If evaporator is replaced, add compressor oil to evaporator.
      3. Add 40 cc (1.4 fl.oz.) 
      4. Compressor oil: ND-OIL 8 or equivalent 
    4. Remove Insulator From Heater Case 
    5. Remove Air Duct 
RENDER: 1.0x

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

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  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.