Toyota 88501-08020 EVAPORATOR Sub-Assembly, Cooler

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This is a difficult procedure for the home mechanic and involves removal of the dashboard. There are a number of hard-to-reach fasteners and many electrical connectors. For the front evaporator, the air conditioning system needs to be discharged and recovered by a technician. The receiver line and suction line should be disconnected from the evaporator, and the refrigerant lines at the firewall should be removed. The glove compartment and right side lower dash panel should be removed, followed by disconnecting the electrical connectors from the evaporator housing. Under the dash, the cooling unit should be secured to the firewall with rivets, bolts, and a nut. The housing should be separated to remove the evaporator core, and the thermostat sensor and expansion valve should be removed if necessary. For installation, new O-rings should be installed and coated with R-134a refrigerant oil. The system should be evacuated, charged, and leak tested by a technician. For the rear evaporator, the rear heating/air conditioning unit should be removed. The unit case should be separated to remove the evaporator. New O-rings should be installed and coated with refrigerant oil. The system should be evacuated, charged, and leak tested by a technician. For five-door models, the rear cooling unit is located separately from the rear heating unit. The air conditioning system should be discharged and the refrigerant recovered. The rear seats, scuff plate, upper quarter panel trim, and rear quarter trim panel should be removed. From beneath the vehicle, the refrigerant lines should be disconnected. The rear cooling unit should be removed by removing the mounting bolts. The cooling unit housing should be separated to remove the evaporator. Installation is the reverse of removal, with new O-rings and refrigerant oil. The system should be evacuated, charged, and leak tested by a technician.