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HOMESERVICE MANUALSTOYOTA2004MATRIX XR, FWD, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 536 (AIR CONDITIONING SYSTEM)REAR COOLING UNITDISASSEMBLY

2004 Toyota Matrix XR, FWD, Standard

Rear Cooling Unit: Disassembly

2004 Toyota Matrix XR, FWD, StandardSECTION Disassembly

WARNING: This page is about a different car, the 2003 Lexus LS 430. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE AIR REFINER FILTER
REMOVE BLOWER SPEED CONTROL
REMOVE REAR DAMPER SERVOMOTOR
REMOVE BLOWER RESISTOR
REMOVE DRAIN HOSE
REMOVE COOLING BOX
1. W/Cool box models:
  Remove the 3 screws, clip and 2 ducts.
2. Disconnect the connector.
3. Remove the screw and cooling box light.
4. Remove the cooling box.
  
  Fig 1: Removing Cooling Box
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SMOKE SENSOR
1. Disconnect the connector.
2. Remove the 4 screws and smoke sensor.
  
  Fig 2: Removing Smoke Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR DUCT
Remove the 3 screws and duct.

Fig 3: Removing Air Duct
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BLOWER MOTOR
1. Remove the 4 screws and filter case.
2. Disconnect the connector.
  
  Fig 4: Removing Filter Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 3 screws and blower motor.
  
  Fig 5: Removing Blower Motor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the nut and fan.
REMOVE WIRE HARNESS

Fig 6: Removing Nut & Fan
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EVAPORATOR
1. Remove the 4 screws and cooler case.
2. Remove the evaporator.
HINT:

At the time of reassembly, please refer to the following item. 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 7: Removing Evaporator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXPANSION VALVE W/ MAGNETIC VALVE
Using a hexagon wrench (5.0 mm, 0.20 in.), remove the 2 bolts, tube and expansion valve.

Torque: 3.5 N.m (36 kgf.cm, 31 in.lbf)

NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system.

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 tube.

Fig 8: Removing Expansion Valve (With Magnetic Valve)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002