This procedure covers removal and replacement of the A/C evaporator core, which requires complete dashboard removal and A/C system discharge/recharge.

Warnings

Tools required

Parts

• A/C Evaporator Core × 1 — Use OEM specification
• A/C system O-ring set × 1 — Use OEM specification
• Expansion valve O-rings × 1 — Use OEM specification
• Refrigerant R134a × 1 — Approximately 16-18 oz per system spec
• PAG oil (ND-Oil 11 or equivalent) × 1 — Use OEM specification
• Dashboard fastener clips × 1 — Replace any broken clips

Fluids

• Toyota Super Long Life Coolant (Pink) — 1 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery terminal and wait 90 seconds for airbag system discharge
3. Recover A/C refrigerant using certified recovery equipment
4. Drain engine coolant to below heater core level using radiator drain cock
5. Remove both front seats for dashboard access (four 14mm bolts per seat)
6. Disconnect steering column coupler bolt and mark alignment
7. Remove all dashboard trim panels including glove box, center console, and instrument cluster bezel

Procedure

1. 1

   Disconnect A/C Lines at Firewall
   From engine bay, disconnect the A/C liquid and suction lines at the firewall connections. Cap all openings immediately with plastic caps or tape to prevent moisture and debris entry. Remove the two line fittings using a flare nut wrench to prevent rounding.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
2. 2

   Disconnect Heater Hoses
   Disconnect both heater hoses at the firewall. Coolant will drain so have a container ready. Use hose clamp pliers to remove spring clamps. Cap hoses to prevent additional coolant loss.
   ⚠Hot coolant can cause burns. Ensure engine is completely cool before disconnecting heater hoses.
3. 3

   Remove Steering Column and Disconnect Wiring
   Remove the four steering column mounting bolts. Lower the column carefully without disconnecting wiring. Label and disconnect all electrical connectors from the dashboard harness including airbag connectors (yellow), instrument cluster harness, HVAC controls, and radio antenna. Support steering column on a padded surface.
   ⚠️Handle airbag connectors with care. Do not probe airbag connector terminals or apply electrical power to airbag circuits.
4. 4

   Remove Dashboard Mounting Bolts
   Remove all dashboard mounting bolts and nuts. Typical locations include: two bolts at each A-pillar, four bolts across top edge near windshield, two bolts at center support bracket, and two nuts at firewall near blower motor area. Keep fasteners organized by location.
   Torque spec

   Mounting Bolts26 Nm (19 lb-ft)
5. 5

   Extract Dashboard Assembly
   With an assistant, carefully pull dashboard rearward and lift out of vehicle. Check for any remaining connectors or fasteners. Dashboard is bulky but not extremely heavy. Set on a protected surface with passenger side up for evaporator access.
   ⚠Dashboard is fragile once removed from vehicle. Support all sections to prevent cracking at mounting points.
6. 6

   Remove Blower Motor and Resistor
   With dashboard inverted on work surface, remove blower motor by disconnecting electrical connector and removing three mounting screws. Remove blower motor resistor/power transistor assembly. This provides access to evaporator case.
   Torque spec

   Cover Screws10 Nm (8 lb-ft)
7. 7

   Remove Evaporator Case Cover
   Remove all screws securing the evaporator case cover (passenger side of HVAC unit). Carefully separate the case halves. The expansion valve will be visible on the evaporator inlet.
   Torque spec

   Evaporator Case Screws5 Nm (4 lb-ft)
8. 8

   Remove Expansion Valve
   Disconnect the expansion valve from the evaporator. Remove the two bolts securing the valve and carefully extract it with the thermal sensing bulb attached. Inspect O-rings for damage and discard. Cap evaporator openings immediately.
   ⚠Do not bend or damage the thermal sensing bulb capillary tube. This will require expansion valve replacement.
   Torque spec

   Expansion Valve10 Nm (7 lb-ft)
9. 9

   Extract Old Evaporator Core
   Carefully slide the evaporator core out of the case. Note the orientation and position of any foam seals or insulation. Inspect the case for debris, leaves, or moisture that could indicate drainage issues. Clean case thoroughly if contamination is present.
   ℹ️Inspect old evaporator for signs of leak location. Aluminum corrosion typically occurs at inlet/outlet connections or on bottom edge where moisture collects.
10. 10

    Prepare and Install New Evaporator
    Transfer all foam seals and temperature sensors from old evaporator to new unit. Install new O-rings on evaporator inlet and outlet tubes, coating with fresh PAG oil. Carefully slide new evaporator into case ensuring proper orientation and that all seals are correctly positioned.
    ⚠Add specified amount of PAG oil to new evaporator (typically 1.4-2.0 oz). Consult service manual for exact capacity based on system oil loss.
11. 11

    Install Expansion Valve
    Install new O-rings on expansion valve, coating with PAG oil. Attach expansion valve to evaporator ensuring thermal sensing bulb is correctly positioned against evaporator outlet tube. Torque bolts to specification and verify valve is secure.
    Torque spec

    Expansion Valve10 Nm (7 lb-ft)
12. 12

    Reassemble Evaporator Case
    Carefully align and close evaporator case halves. Install all case screws and torque to specification. Reinstall blower motor resistor and blower motor assembly. Verify all components are secure and electrical connectors are attached.
    Torque spec

    Evaporator Case Screws5 Nm (4 lb-ft)

    Cover Screws10 Nm (8 lb-ft)
13. 13

    Reinstall Dashboard Assembly
    With assistant, position dashboard into vehicle. Route all wiring harnesses through proper openings. Align dashboard to mounting points and install all mounting bolts and nuts finger-tight first, then torque to specification. Reconnect all electrical connectors using photos as reference.
    Torque spec

    Mounting Bolts26 Nm (19 lb-ft)
14. 14

    Reconnect Steering and HVAC Lines
    Reinstall steering column and torque bolts to specification. Reconnect steering coupler bolt at alignment marks. From engine bay, install new O-rings on A/C line fittings with PAG oil coating. Connect A/C lines and torque to specification. Reconnect heater hoses with new clamps.
    Torque spec

    AC Line Fittings20 Nm (15 lb-ft)
15. 15

    Evacuate and Recharge A/C System
    Connect vacuum pump to A/C system and evacuate for minimum 45 minutes to remove all moisture and air. System should hold vacuum for 30 minutes without loss. Recharge system with specified amount of R134a refrigerant (verify on underhood label, typically 16-18 oz). Add UV dye if desired for future leak detection.
    ⚠Improper evacuation will leave moisture in system causing corrosion and compressor damage. Vacuum must hold steady for 30 minutes minimum.

Reassembly

1. Reinstall front seats and torque mounting bolts to specification
2. Refill cooling system with Toyota Super Long Life Coolant (Pink) to proper level
3. Reconnect negative battery terminal
4. Install all dashboard trim panels, glove box, and center console components
5. Verify all electrical functions: airbag light should extinguish after initialization, all gauges functional, HVAC controls operational

Verification

• Start engine and verify no coolant leaks at heater hose connections
• Run A/C system and verify cold air output from all vents within 2-3 minutes
• Check A/C pressures with manifold gauges: low side should be 25-35 psi, high side 200-250 psi at idle with ambient temp 70-80°F
• Inspect all A/C line fittings for refrigerant leaks using leak detector
• Verify blower motor operates at all speeds without noise
• Test all dashboard functions including airbag warning light (should illuminate then extinguish), gauges, and indicator lights
• Verify HVAC system switches between modes (defrost, floor, vent) properly
• Check for proper condensate drainage - water should drip from evaporator drain tube under vehicle after 10-15 minutes of A/C operation

More procedures for this vehicle