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Home >> Toyota >> 2005 >> Avalon XLS >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> Heater & Air Conditioner >> Air Conditioning Radiator ASSY >> Overhaul

Air Conditioning Radiator ASSY: Overhaul

HINT:

  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 

    Wait for 90 seconds after disconnecting the cable to prevent the airbag working.

  2. REMOVE FR WIPER ARM & BLADE ASSY LH (SEE  REPLACEMENT  ) 
  3. REMOVE FR WIPER ARM & BLADE ASSY RH (SEE  REPLACEMENT  ) 
  4. REMOVE COWL TOP VENTILATOR LOUVER RH (SEE  REPLACEMENT  ) 
  5. REMOVE WINDSHIELD WIPER MOTOR & LINK ASSY (SEE  REPLACEMENT  ) 
  6. REMOVE COWL TOP OUTSIDE PANEL FRONT 
    1. Remove the 4 bolts, 2 nuts and cowl top outside panel front.
      Fig 1: Removing Bolts, Nuts & Cowl Top Outside Panel Front
      G02974237Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (SEE  REPLACEMENT  ) 

    SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)

  8. DISCONNECT SUCTION HOSE SUB-ASSY 
    1. Remove the bolt, and slide the hook connector.
    2. Disconnect the suction hose sub-assy.
    3. Remove the O-ring from the suction hose sub-assy.
    NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
    9. Fig 2: Removing Bolt, & Slide Hook Connector
    G02974238Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. DISCONNECT AIR CONDITIONER TUBE & ACCESSORY 
    1. Disconnect the air conditioner tube & accessory.
    2. Remove the O-ring from the air conditioner tube & accessory.
    NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
  10. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) 
    1. Slide the clip and disconnect the heater water outlet hose A.
    NOTE:
    • Do not apply excessive force to the heater water outlet hose A.
    • Prepare a drain pan or cloth in case the cooling water leaks.
  11. DISCONNECT HEATER WATER INLET HOSE A 
    1. Slide the clip and disconnect the heater water inlet hose A.
    NOTE:
    • Do not apply excessive force to the heater water inlet hose A.
    • Prepare a drain pan or cloth in case the cooling water leaks.
      Fig 3: Disconnecting Heater Water Inlet Hose A
      G02974239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY W/FRONT PASSENGER AIRBAG ASSY (SEE  REPLACEMENT  ) 

    HINT:

    Refer to the removal procedures for the instrument panel safety pad sub-assy w/front passenger airbag assy.

  13. REMOVE HEATER TO REGISTER DUCT NO.2 
    1. Remove the 3 clips and heater to register duct No.2.
      Fig 4: Removing Clips & Heater To Register Duct No.2
      G02974240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE HEATER TO REGISTER DUCT ASSY NO.6 
    1. Disengage the 4 claws and then remove the heater to register duct No.6
      Fig 5: Disengaging Claws & Then Remove Heater To Register Duct No.6
      G02974241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE CONSOLE BOX DUCT NO.1 
    1. Remove the clip and console box duct No.1.
      Fig 6: Removing Clip & Console Box Duct No.1
      G02974242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE FLOOR CARPET BRACKET LH 
    1. Release the 2 clamps.
    2. Turn back the floor carpet.
      Fig 7: Removing Clamps
      G02974243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 3 clips.
    4. Remove the floor carpet bracket LH.
      Fig 8: Removing Clips
      G02974244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE FLOOR CARPET BRACKET RH 
    1. Release the 3 clamps.
    2. Turn back the floor carpet.
      Fig 9: Removing Clamps
      G02974245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 3 clips.
    4. Remove the floor carpet bracket RH.
      Fig 10: Removing Clips
      G02974246Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE AIR DUCT REAR NO.2 
    1. Release the 2 claws and remove the air duct rear No.2.
      Fig 11: Removing Claws & Remove Air Duct Rear No.2
      G02974247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE AIR DUCT REAR NO.1 
    1. Release the 2 claws and remove the air duct rear No.1.
      Fig 12: Removing Claws & Remove Air Duct Rear No.1
      G02974248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE AIR DUCT SUB-ASSY NO.1 (SEE  OVERHAUL  ) 
  21. SEPARATE STEERING INTERMEDIATE SHAFT ASSY (SEE  OVERHAUL  ) 
  22. REMOVE STEERING COLUMN ASSY (SEE  OVERHAUL  ) 
  23. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSY 
    1. Disconnect each connector and remove each clamp. Disconnect the wire harness.
    2. Remove the 6 nuts and 3 bolts.
      Fig 13: Disconnecting Each Connector & Remove Each Clamp
      G02974249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 3 bolts and nut.
    4. Using a Torx® socket wrench (T40), remove the 5 Torx® bolts.

      HINT:

      The Torx® bolts on the passenger side can be removed with the collar or for adjustment.

    5. Using a hexagon wrench 12 mm, remove the 2 collars and instrument panel reinforcement assy with the air conditioner unit assy.
      Fig 14: Removing Torx Bolts
      G02974250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 3 bolts, 2 screws and instrument panel reinforcement assy.
      Fig 15: Removing Bolts, Screws & Instrument Panel Reinforcement Assy
      G02974251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE AIR DUCT SUB-ASSY NO.2 
    1. Release the 2 claws and remove the air duct sub-assy N0.2 as shown in the illustration.
      Fig 16: Removing Claws & Remove Air Duct Sub-Assy N0.2
      G02974252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE BLOWER ASSY (SEE  OVERHAUL  ) 
  26. REMOVE AIR OUTLET CONTROL SERVOMOTOR 
    1. Disconnect the 2 connectors and remove the air conditioner harness.
      Fig 17: Disconnecting Connectors & Remove Air Conditioner Harness
      G02974253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 screws and then the air outlet control servomotor.
      Fig 18: Removing Screws & Then Air Outlet Control Servomotor
      G02974254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE AIR MIX CONTROL SERVOMOTOR 
    1. Remove the 2 screws and air mix control servomotor.
      Fig 19: Removing Screws Air Mix Control Servomotor
      G02974255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE HEATER RADIATOR UNIT SUB-ASSY 
    1. Remove the screw and clamp.
    2. Release the 4 claws and remove the clamp.
      Fig 20: Removing Claws & Remove Clamp
      G02974256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the heater radiator unit sub-assy from the air conditioning radiator assy.
      NOTE: Prepare a drain pan or cloth in case the cooling water leaks.
      Fig 21: Removing Heater Radiator Unit Sub-Assy From Air Conditioning Radiator Assy
      G02974257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE COOLER AIR HOSE 
    1. Remove the cooler air hose with the cooler (room temp. sensor) thermistor.
    2. Remove the cooler air hose from the cooler (room temp, sensor) thermistor.
      Fig 22: Removing Cooler Air Hose
      G02974258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE ASPIRATOR 
    1. Disengage the 2 claws and then remove the aspirator.
      Fig 23: Disengaging Claws & Removing Aspirator
      G02974259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSY 
    1. Install the air conditioner unit assy to the instrument panel reinforcement assy with the 2 screws and 3 bolts.

      Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf) (BOLT) 

      NOTE: Tighten the bolts and screws in the order shown in the illustration to install the air conditioner unit assy.
      Fig 24: Installing Air Conditioner Unit Assy To Instrument Panel Reinforcement Assy With Screws & Bolts
      G02974260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Driver seat:
      1. Using a Torx® socket wrench (T40), install the instrument panel reinforcement assy with the 3 Torx® bolts.

        Torque: 17 N.m (173 kgf.cm, 13 ft.lbf) 

    3. Passenger seat:
      1. Using a hexagon wrench 12 mm, install the instrument panel reinforcement assy with the 2 bolts.

        Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf) 

      2. Using a Torx® socket wrench (T40), install the instrument panel reinforcement assy with the 2 Torx® bolts.

        Torque: 20 N.m (204 kgf.cm, 15 in.lbf) 

    4. Install the 3 bolts and nut.

      Torque: 

      NUT: 9.8 N.m (100 kgf.cm, 87 in.lbf) 

      BOLT A: 20 N.m (204 kgf.cm, 15 ft.lbf) 

      Fig 25: Installing Bolts & Nut
      G02974261Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the connectors and clamps.
    6. Install the 6 nuts and 3 bolts.
      Fig 26: Installing Nuts & Bolts
      G02974262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL STEERING INTERMEDIATE SHAFT ASSY (SEE  OVERHAUL  ) 
  33. INSTALL STEERING COLUMN ASSY (SEE  OVERHAUL  ) 
  34. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY W/FRONT PASSENGER AIRBAG ASSY (SEE  REPLACEMENT  ) 

    HINT:

    Refer to the instructions for installation of the instrument panel safety pad sub-assy w/front passenger air-bag assy.

  35. INSTALL AIR CONDITIONER TUBE & ACCESSORY 
    1. Remove the attached vinyl tape from the tube.
    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioning tube assy.

      Compressor oil: ND-OIL 8 or equivalent 

    3. Install the O-ring on the liquid tube sub-assy.
    4. Install the liquid tube sub-assy.
  36. INSTALL SUCTION HOSE SUB-ASSY 
    1. Remove the attached vinyl tape from the hose.
    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction hose sub-assy.

      Compressor oil: ND-OIL 8 or equivalent 

    3. Install the O-ring on the suction hose sub-assy.
      Fig 27: Removing Bolt
      G02974263Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Move the hook connector in the direction indicated by the arrow in the illustration.
    5. Insert the pipe joint into the fitting hole securely and tighten the bolt.

      Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf) 

  37. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  38. PERFORM INITIALIZATION (SEE  INITIALIZATION  ) 

    Some systems need initialization when disconnecting the cable from the negative battery terminal.

  39. ADD ENGINE COOLANT (SEE  COOLANT (2GR-FE)  ) 
  40. CHECK FOR ENGINE COOLANT LEAKS (SEE  ON-VEHICLE INSPECTION  ) 
  41. CHARGE REFRIGERANT (SEE  REPLACEMENT  ) 

    SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)

    Specified amount: 450 to 550 g (15.9 to 19.4 oz.) 

  42. WARM UP ENGINE (SEE  REPLACEMENT  ) 
  43. CHECK FOR LEAKAGE OF REFRIGERANT (SEE  REPLACEMENT  ) 
  44. INSTALL WINDSHIELD WIPER MOTOR & LINK ASSY (SEE  REPLACEMENT  ) 
  45. INSTALL FR WIPER ARM & BLADE ASSY RH (SEE  REPLACEMENT  ) 
  46. INSTALL FR WIPER ARM & BLADE ASSY LH (SEE  REPLACEMENT  ) 
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