This procedure involves removing the dashboard and HVAC housing to replace the AC evaporator core, including evacuating and recharging the AC system.

Warnings

Tools required

Parts

• AC evaporator core × 1 — 88501-0R070 or equivalent
• Expansion valve O-rings × 1 — Use OEM specification
• AC line O-rings × 2 — Use OEM specification
• PAG oil for AC system × 1 — ND-11 (30-50ml)
• R-1234yf refrigerant × 1 — Use OEM specification
• Evaporator case seal × 1 — Use OEM specification
• Dashboard clips and fasteners × 1 — Assorted as needed

Fluids

• Toyota Super Long Life Coolant (Pink) — 0.5 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Disconnect negative battery terminal and wait 90 seconds for airbag system to discharge
3. Recover AC refrigerant using approved R-1234yf recovery machine
4. Drain coolant from radiator drain valve into suitable container
5. Place protective covers on front seats and floor to prevent damage during dashboard removal
6. Take detailed photos of dashboard, wiring, and connector locations before disassembly
7. Label all electrical connectors with tape and marker as they are disconnected

Procedure

1. 1

   Remove center console and lower trim
   Remove cup holder insert and two screws beneath. Remove shift knob (pull firmly upward on electronic shifter trim). Remove center console side panels by pulling outward at rear clips. Remove four console mounting screws and disconnect USB and 12V connectors. Lift console up and rearward to remove. Remove lower dashboard trim panels on both driver and passenger sides by releasing clips.
2. 2

   Remove steering column covers and instrument cluster
   Remove two screws from lower steering column cover and separate upper/lower covers. Disconnect hood release cable. Tilt steering wheel to lowest position. Remove four bolts securing steering column to dashboard. Lower column and support with wire or strap. Remove instrument cluster bezel by releasing clips. Remove four screws securing instrument cluster, pull forward, and disconnect three electrical connectors. Remove cluster.
3. 3

   Disconnect dashboard wiring and connectors
   Disconnect all remaining electrical connectors from dashboard harness including: climate control module, radio, hazard switch, passenger airbag connector (yellow), glove box light, and all under-dash connectors. Disconnect three ground points on driver side. Release wiring harness from all dashboard clips. Pull harness through to engine bay side for clearance.
4. 4

   Remove instrument panel reinforcement
   From engine bay, disconnect two AC lines from expansion valve at firewall using two wrenches (one to hold, one to turn). Cap openings immediately to prevent contamination. Disconnect two heater hoses from heater core pipes at firewall. Remove three dashboard mounting nuts from firewall studs (two on driver side, one center). Inside vehicle, remove two dashboard mounting bolts at each A-pillar (four total). Remove two bolts at center tunnel. Carefully pull dashboard assembly rearward to clear windshield and remove from vehicle with assistant.
5. 5

   Remove HVAC unit from vehicle
   With dashboard removed, locate HVAC unit mounted to firewall. Disconnect blower motor connector and climate control actuator connectors (mode door, air mix door). Remove one grounding bolt. Remove four mounting bolts securing HVAC unit to firewall. Carefully pull HVAC unit straight back to clear evaporator pipes and drain tube from firewall. Lower unit and remove from vehicle.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
6. 6

   Disassemble HVAC case
   Place HVAC unit on clean workbench. Remove blower motor assembly (three screws). Remove mode door actuator and air mix door actuator (two screws each). Remove evaporator temperature sensor from evaporator fins (pull gently). Remove metal clips securing case halves together (typically 6-8 spring clips around perimeter). Carefully separate upper and lower case halves.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
7. 7

   Remove expansion valve and old evaporator
   Remove two screws securing expansion valve bracket to evaporator. Carefully remove expansion valve from evaporator pipes noting orientation. Remove and discard O-rings from expansion valve. Remove evaporator case screws securing evaporator support brackets. Carefully lift old evaporator out of lower case half, taking care not to damage case or remaining components. Note orientation and position of evaporator for installation of new unit.
   Torque spec

   Expansion Valve10 Nm (7 lb-ft)

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

   Prepare and install new evaporator
   Clean HVAC case halves thoroughly, removing any debris or old foam seals. Inspect heater core and case for damage. Install new evaporator case seal on lower case half. Pour 30-40ml of ND-11 PAG oil into inlet tube of new evaporator (distribute oil internally by tilting). Place new evaporator into lower case half in same orientation as original. Secure with evaporator case screws to specified torque.
   Torque spec

   Evaporator Case Screws5 Nm (4 lb-ft)
9. 9

   Install expansion valve
   Install new O-rings onto expansion valve fittings, lubricating lightly with PAG oil. Connect expansion valve to evaporator pipes in original orientation. Secure expansion valve bracket with two screws to specified torque. Reinstall evaporator temperature sensor into evaporator fins ensuring proper contact.
   Torque spec

   Expansion Valve10 Nm (7 lb-ft)
10. 10

    Reassemble HVAC case
    Verify all actuators, doors, and linkages move freely. Apply new foam seal to case mating surfaces if original is damaged. Carefully align upper and lower case halves ensuring no wires or components are pinched. Secure case halves with all metal spring clips. Reinstall blower motor assembly. Reinstall all actuators (mode door, air mix door) ensuring proper engagement with linkage arms.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)
11. 11

    Reinstall HVAC unit to vehicle
    Position HVAC unit near firewall opening. Guide evaporator pipes and drain tube through firewall carefully. Align unit to firewall and mounting studs. Install four mounting bolts to specified torque. Reconnect all climate control actuator connectors and blower motor connector. Install grounding bolt.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
12. 12

    Reinstall dashboard assembly
    With assistant, position dashboard assembly into vehicle. Guide dashboard onto mounting studs and align to windshield opening. Install two bolts at each A-pillar and two bolts at center tunnel. From engine bay, install three dashboard mounting nuts on firewall studs. Verify dashboard is fully seated and aligned before final tightening. Reconnect all dashboard wiring harnesses, ground points, and electrical connectors using labels and photos as reference.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
13. 13

    Connect AC lines and heater hoses
    Install new O-rings onto AC line fittings and lubricate with PAG oil. Connect AC lines to expansion valve at firewall, hand-tightening first to ensure proper thread engagement. Torque AC line fittings to specification using two wrenches (one to hold valve body, one to tighten fitting). Reconnect heater hoses to heater core pipes at firewall and secure with hose clamps.
    Torque spec

    AC Line Fittings20 Nm (15 lb-ft)
14. 14

    Evacuate and recharge AC system
    Connect manifold gauge set to AC service ports. Connect vacuum pump and evacuate system for minimum 45 minutes (1 hour recommended). Close valves and monitor vacuum for 15 minutes to verify no leaks (vacuum should hold steady). Recharge system with R-1234yf refrigerant to specification (approximately 500-550g total, verify on underhood label). Add additional PAG oil through service port if required per recovery machine reading.
15. 15

    Complete interior reassembly
    Reinstall instrument cluster and connect all connectors. Install cluster bezel. Reinstall steering column to dashboard and torque four bolts to specification. Install steering column covers and reconnect hood release. Install all lower dashboard trim panels. Reinstall center console, connecting all electrical connectors. Install console mounting screws. Reconnect negative battery terminal. Refill coolant to proper level and bleed cooling system.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)

Reassembly

1. Double-check all electrical connectors are properly seated and locked
2. Verify all dashboard mounting bolts and nuts are properly torqued
3. Ensure no tools or parts remain inside dashboard or HVAC housing
4. Verify all trim panels and console components snap into place correctly
5. Check that all actuator linkages move freely before testing

Verification

• Reconnect battery and clear any diagnostic codes using scan tool
• Start engine and verify no coolant leaks from heater core connections
• Test all climate control functions: fan speeds, mode selection, temperature control
• Verify AC compressor engages and cold air is produced within 2-3 minutes
• Check AC vent temperature with thermometer (should reach 40-45°F at center vents)
• Inspect all AC line connections at firewall for refrigerant leaks using leak detector
• Test all dashboard functions: gauges, lights, switches, radio, hazard lights
• Verify no rattles or unusual noises from dashboard or HVAC system
• Check passenger airbag light illuminates briefly at startup then extinguishes
• Road test vehicle and verify AC performance under load

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