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Replacing evaporator

Tiny
NASER NASER
  • MEMBER
  • 2010 TOYOTA HIGHLANDER
  • V6
  • 2WD
  • 183,000 MILES
I have an A/C leak underneath the dash on passenger side. I used the leak detector to find it. Can you provide any instructions? I know dash has to come out.
Thursday, March 25th, 2021 AT 8:48 AM

13 Replies

Tiny
ASEMASTER6371
  • MECHANIC
  • 52,797 POSTS
Hello again my friend,

I attached the procedure below for you. You have a big job ahead of you as this is a tough one.

https://www.2carpros.com/articles/air-conditioner-leak-detection

Roy

AIR CONDITIONING: FRONT COOLING UNIT: REMOVAL

1. PRECAUTION

See: Dashboard / Instrument Panel > Vehicle Damage Warnings > Instrument Panel Safety Pad

2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM See: Heating and Air Conditioning > Removal and Replacement > Replacement

3. POSITION FRONT WHEELS STRAIGHT AHEAD

4. REMOVE FRONT WHEEL LH

5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION:
Wait for 90 seconds after disconnecting the cable to prevent the airbag from deploying See: Air Bag Systems > Vehicle Damage Warnings

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected See: Vehicle > Programming and Relearning > Repair Instruction - Initialization

6. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH See: Wiper Motor > Removal and Replacement > Removal

7. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH See: Wiper Motor > Removal and Replacement > Removal

8. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY See: Wiper Motor > Removal and Replacement > Removal

9. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY See: Wiper Motor > Removal and Replacement > Removal

10. REMOVE COWL TOP OUTER PANEL SUB-ASSEMBLY See: Suspension Strut / Shock Absorber > Removal and Replacement > Removal

11. DISCONNECT HEATER WATER HOSE OUTLET

(a)Using pliers, grip the claws of the clip and slide the clip to disconnect the heater outlet water hose.

imageOpen In New TabZoom/Print

NOTICE:
* Do not apply excessive force to the heater outlet water hose.
* Prepare a drain pan or cloth in case the coolant leaks.
12. DISCONNECT HEATER WATER HOSE INLET

(a)Using pliers, grip the claws of the clip and slide the clip to disconnect the heater inlet water hose.

imageOpen In New TabZoom/Print

NOTICE:
* Do not apply excessive force to the heater inlet water hose.
* Prepare a drain pan or cloth in case the coolant leaks.
13. DISCONNECT COOLER REFRIGERANT LIQUID PIPE A

(a)Remove the bolt, and slide the hook connector.

imageOpen In New TabZoom/Print

(b)Disconnect the cooler refrigerant liquid pipe A.

(c)Remove the O-ring from the cooler refrigerant liquid pipe A.

NOTICE:
Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

14. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION PIPE

(a)Disconnect the No. 1 cooler refrigerant suction pipe.

(b)Remove the O-ring from the No. 1 cooler refrigerant suction pipe.

NOTICE:
Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

15. REMOVE LOWER NO. 3 STEERING WHEEL COVER See: Air Bag > Removal and Replacement > Removal

16. REMOVE LOWER NO. 2 STEERING WHEEL COVER See: Air Bag > Removal and Replacement > Removal

17. REMOVE STEERING PAD See: Air Bag > Removal and Replacement > Removal

18. REMOVE STEERING WHEEL ASSEMBLY See: Steering Wheel > Removal and Replacement > Removal

19. REMOVE STEERING COLUMN COVER See: Steering Column > Removal and Replacement > Removal

20. REMOVE TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY See: Steering Column > Removal and Replacement > Removal

21. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Cluster / Carrier > Removal and Replacement > Removal

22. REMOVE COMBINATION METER ASSEMBLY See: Instrument Cluster / Carrier > Removal and Replacement > Removal

23. REMOVE CENTER INSTRUMENT PANEL REGISTER ASSEMBLY See: Dashboard / Instrument Panel > Removal and Replacement > Removal

24. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (w/o Smart Key System) See: Dashboard / Instrument Panel > Removal and Replacement > Removal

25. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (w/ Smart Key System) See: Dashboard / Instrument Panel > Removal and Replacement > Removal

26. REMOVE HEATER CONTROL AND ACCESSORY ASSEMBLY (for Manual Air Conditioning System) See: Control Assembly, HVAC > Removal and Replacement > Removal

27. REMOVE AIR CONDITIONING CONTROL ASSEMBLY (for Automatic Air Conditioning System) See: Control Assembly, HVAC > Removal and Replacement > Removal

28. REMOVE RADIO RECEIVER ASSEMBLY WITH BRACKET (w/o Navigation System) See: Radio/Stereo > Removal and Replacement > Removal

29. REMOVE NAVIGATION RECEIVER ASSEMBLY WITH BRACKET (w/ Navigation System) See: Navigation System > Removal and Replacement > Removal

30. REMOVE FRONT DOOR SCUFF PLATE LH See: Headliner > Removal and Replacement > Removal

31. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH See: Headliner > Removal and Replacement > Removal

32. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (for Manual Air Conditioning System) See: Dashboard / Instrument Panel > Removal and Replacement > Removal

33. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (for Automatic Air Conditioning System) See: Dashboard / Instrument Panel > Removal and Replacement > Removal

34. REMOVE FRONT DOOR SCUFF PLATE RH See: Headliner > Removal and Replacement > Removal

35. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH See: Headliner > Removal and Replacement > Removal

36. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY See: Dashboard / Instrument Panel > Removal and Replacement > Removal

37. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY See: Dashboard / Instrument Panel > Removal and Replacement > Removal

38. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Dashboard / Instrument Panel > Removal and Replacement > Removal

39. REMOVE NO. 2 CONSOLE BOX DUCT (w/o Rear Air Conditioning System) See: Dashboard / Instrument Panel > Removal and Replacement > Removal

40. REMOVE LOWER REAR CONSOLE BOX See: Console > Removal and Replacement > Removal

41. REMOVE CONSOLE BOX ASSEMBLY (w/o Rear Air Conditioning System) See: Console > Removal and Replacement > Removal

42. REMOVE CONSOLE BOX ASSEMBLY (w/ Rear Air Conditioning System) See: Console > Removal and Replacement > Removal

43. REMOVE FRONT NO. 1 CONSOLE BOX INSERT See: Dashboard / Instrument Panel > Removal and Replacement > Removal

44. REMOVE FRONT NO. 2 CONSOLE BOX INSERT See: Dashboard / Instrument Panel > Removal and Replacement > Removal

45. REMOVE ENGINE SWITCH (w/ Smart Key System) See: Ignition Switch > Removal and Replacement > Removal

46. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH See: Headliner > Removal and Replacement > Removal

47. REMOVE FRONT PILLAR GARNISH LH See: Headliner > Removal and Replacement > Removal

48. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH See: Headliner > Removal and Replacement > Removal

49. REMOVE FRONT PILLAR GARNISH RH See: Headliner > Removal and Replacement > Removal

50. REMOVE NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY See: Dashboard / Instrument Panel > Removal and Replacement > Removal

51. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side) See: Speaker > Removal and Replacement > Removal

52. REMOVE NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY See: Dashboard / Instrument Panel > Removal and Replacement > Removal

53. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side) See: Speaker > Removal and Replacement > Removal

54. DISCONNECT INSTRUMENT PANEL WIRE ASSEMBLY See: Air Bag > Removal and Replacement > Removal

55. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for Pole Antenna Type) See: Dashboard / Instrument Panel > Removal and Replacement > Removal

56. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for Glass Antenna Type) See: Dashboard / Instrument Panel > Removal and Replacement > Removal

57. REMOVE BRAKE PEDAL RETURN SPRING See: Brake Pedal Assy > Removal and Replacement > Removal

58. REMOVE STOP LIGHT SWITCH ASSEMBLY See: Brake Light Switch > Removal and Replacement > Removal

59. SEPARATE BRAKE MASTER CYLINDER PUSH ROD CLEVIS See: Brake Pedal Assy > Removal and Replacement > Removal

60. REMOVE BRAKE PEDAL SUPPORT SUB-ASSEMBLY See: Brake Pedal Assy > Removal and Replacement > Removal

61. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY See: Air Bag > Removal and Replacement > Removal

62. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY See: Steering Column > Removal and Replacement > Removal

63. SEPARATE STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY See: Steering Column > Removal and Replacement > Removal

64. REMOVE STEERING COLUMN ASSEMBLY See: Steering Column > Removal and Replacement > Removal

65. DISCONNECT INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY

(a)Remove the 3 nuts and disconnect the instrument panel junction block assembly.

imageOpen In New TabZoom/Print

66. REMOVE POWER STEERING ECU ASSEMBLY See: Steering Control Module > Removal and Replacement > Removal

67. REMOVE CERTIFICATION ECU (SMART KEY ECU ASSEMBLY) (w/ Smart Key System) See: Alarm Module, (Vehicle Antitheft) > Removal and Replacement > Removal

68. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY See: Control Module HVAC > Removal and Replacement > Removal

69. REMOVE REAR NO. 1 AIR DUCT

(a)Disengage the claw.

imageOpen In New TabZoom/Print

(b)Turn back the floor carpet as shown in the illustration.

(c)Remove the clip.

imageOpen In New TabZoom/Print

(d)Disengage the clamp.

(e)Disengage the 2 claws and remove the rear No. 1 air duct.

70. REMOVE REAR NO. 3 AIR DUCT

(a)Disengage the claw.

imageOpen In New TabZoom/Print

(b)Turn back the floor carpet as shown in the illustration.

(c)Remove the clip.

imageOpen In New TabZoom/Print

(d)Disengage the 2 claws and remove the rear No. 3 air duct.

71. REMOVE NO. 1 CONSOLE BOX DUCT (w/o Rear Air Conditioning System)

(a)Remove the clip and the No. 1 console box duct.

imageOpen In New TabZoom/Print

72. REMOVE CENTER HEATER TO REGISTER DUCT

(a)Disengage the clamp.

imageOpen In New TabZoom/Print

(b)Disengage the 4 claws and remove the center heater to register duct.

73. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

(a)Remove the bolt and disconnect the earth wire.

imageOpen In New TabZoom/Print

(b)Disengage each clamp.

(c)Remove the 2 bolts.

imageOpen In New TabZoom/Print

(d)Remove the screw.

(e)Remove the 3 nuts and the No. 1 instrument panel brace sub-assembly.

74. REMOVE NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

(a)Remove the bolt and disconnect the earth wire.

imageOpen In New TabZoom/Print

(b)Disengage each clamp.

(c)Remove the bolt.

imageOpen In New TabZoom/Print

(d)Remove the screw.

(e)Remove the 3 nuts and the No. 2 instrument panel brace sub-assembly.

75. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT (w/o PTC Heater)

(a)Disengage each clamp.

(b)Remove the 2 bolts and disconnect the 2 earth wires.

(c)Disconnect each connector.

(d)Remove the 2 nuts and bolt.

(e)Disconnect the blower motor connector.

imageOpen In New TabZoom/Print

(f)Remove the 2 caps and the 2 bolts from the engine compartment side.

(g)Disconnect the cooler drain hose.

(h)Remove the nut.

imageOpen In New TabZoom/Print

(i)Using a "TORX" socket wrench (T40), remove the 5 "TORX" bolts.

HINT
The "TORX" bolts on the passenger side can be removed with the collars for adjustment.

(j)Using a 12 mm hexagon wrench, remove the 2 collars and the instrument panel reinforcement assembly with air conditioning unit.

(k)Disconnect the connector.

imageOpen In New TabZoom/Print

76. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT (w/ PTC Heater)

(a)Disengage each clamp.

(b)Remove the 2 bolts and disconnect the 2 earth wires.

(c)Disconnect each connector.

(d)Remove the 2 nuts and bolt.

(e)Disconnect the blower motor connector.

(f)Disconnect the 2 quick heater connectors.

imageOpen In New TabZoom/Print

(g)Remove the 2 caps and the 2 bolts from the engine compartment side.

(h)Disconnect the cooler drain hose.

(i)Remove the nut.

imageOpen In New TabZoom/Print

(j)Using a "TORX" socket wrench (T40), remove the 5 "TORX" bolts.

HINT
The "TORX" bolts on the passenger side can be removed with the collars for adjustment.

(k)Using a 12 mm hexagon wrench, remove the 2 collars and the instrument panel reinforcement assembly with air conditioning unit.

(l)Disconnect the connector.

imageOpen In New TabZoom/Print

77. REMOVE AIR CONDITIONING UNIT

(a)Remove the 3 bolts and the air conditioning unit from the instrument panel reinforcement assembly.

imageOpen In New TabZoom/Print
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Thursday, March 25th, 2021 AT 12:14 PM
Tiny
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Ya, I know. This is worse than removing the motor, lol. Done it on a couple of Lexus's before so I am aware of how bad, it is what it is. Thanks for your help.
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Thursday, March 25th, 2021 AT 12:20 PM
Tiny
ASEMASTER6371
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You are welcome.

Always glad to help.

Roy
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Thursday, March 25th, 2021 AT 12:22 PM
Tiny
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Do you know how the A/C blower comes out? I cant see a way at all.
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Friday, March 26th, 2021 AT 7:26 PM
Tiny
ASEMASTER6371
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I attached the procedure below for you.

Roy

AIR CONDITIONING: FRONT BLOWER MOTOR: REMOVAL

1. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY See: Dashboard / Instrument Panel > Removal and Replacement > Removal

2. REMOVE FRONT BLOWER MOTOR SUB-ASSEMBLY

(a)Disconnect the connector.

ImageOpen In New TabZoom/Print

(b)Remove the 3 screws and the front blower motor sub-assembly.
Image (Click to make bigger)
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Saturday, March 27th, 2021 AT 4:28 AM
Tiny
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Finally out, geez this is insane, and I thought German cars are stupid. There is a sensor that sticks into the evaporator on the old one, with 2 teeth, do you know what it's for? I don't know where to install it on the new one. Pictures below.
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Monday, March 29th, 2021 AT 12:13 PM
Tiny
ASEMASTER6371
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That is the evaporator temperature sensor. That prevents icing in the system.

You can mount it the center of the evaporator.

Roy
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Monday, March 29th, 2021 AT 12:18 PM
Tiny
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But inserting it in the evaporator won't poke a hole? Also, the new evaporator did not come with the expansion valve o rings, having a hard time finding it, even new expansion valves do not come with o rings. What is your take on that?
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Monday, March 29th, 2021 AT 12:26 PM
Tiny
ASEMASTER6371
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That is the manufacturer.

It goes in the fins.

Roy
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Monday, March 29th, 2021 AT 12:29 PM
Tiny
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Some expansion valves say front some say rear, they both look the same. What does that mean?
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Monday, March 29th, 2021 AT 12:30 PM
Tiny
ASEMASTER6371
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Those fit other vehicles with some that have rear AC systems. The expansion valves are different.

Roy
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Monday, March 29th, 2021 AT 1:00 PM
Tiny
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So, I did all this together and I have two issues the car will not start nor will the steering wheel turn, it’s locked.
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Saturday, October 9th, 2021 AT 5:54 PM
Tiny
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Okay.
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Sunday, October 10th, 2021 AT 4:09 AM

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