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Home >> Toyota >> 2018 >> Avalon XLE >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> Air Conditioning System (Service Information) (Except Hybrid) >> Air Conditioning Unit >> Installation [10/2015 - ] >> Procedure

Installation [10/2015 - ]: Procedure

  1. INSTALL AIR CONDITIONING UNIT ASSEMBLY 
    1. Install the air conditioning unit assembly to the instrument panel reinforcement assembly with the 3 bolts.
      Fig 1: Tightening Sequence Of Air Conditioning Unit Assembly
      GTY546488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:

      Tighten the bolts in the order shown in the illustration to install the air conditioning unit assembly.

  2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT 
    NOTE:
    • Be sure to support the air conditioning unit assembly when removing it because failure to do so may cause the bracket of the air conditioning unit assembly to break.
    • When installing the air conditioning unit, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.
    1. Engage the 3 guides and temporarily install the instrument panel reinforcement assembly with air conditioning unit as shown in the illustration.
      GTY371781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the instrument panel reinforcement assembly with the 3 bolts <A> and 2 new bolts <B> in the order shown in the illustration.
      GTY571817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Movable Collar *2 Instrument Panel Reinforcement
      *a Body *b Step 1
      *c Step 2 *d Step 3
      *e Step 4 - -

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

      NOTE:

      Tighten the bolts in the order shown in the illustration to install the reinforcement assembly.

    3. Install the bolt <C>.

      Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) 

    4. Install the instrument panel reinforcement assembly with air conditioning unit with the nut.

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

    5. Pass the drain cooler hose through the vehicle securely.
      NOTE:

      Connect the cooler drain hose firmly to prevent water leaks.

    6. Install the 2 bolts.
      Fig 2: Tightening Sequence Of Reinforcement Assembly
      GTY551575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:

      Tighten the bolts in the order shown in the illustration.

    7. Install the 2 hole plugs.
    8. Engage each clamp.
    9. Connect the connector.
    10. Connect the connector holder with the 2 nuts.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

    11. Connect the 3 earth wires with the 3 bolts.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

    12. Engage the claw to connect the airbag sensor assembly connector as shown in the illustration.
      GTY371378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    13. Engage the 2 claws to lock the retainer as shown in the illustration.
      GTY554164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Retainer
    14. Engage each clamp.
      GTY591285Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Airbag Sensor Assembly - -
    15. Connect each connector.
    16. Connect the connector to the airbag sensor assembly as shown in the illustration.
      NOTE:

      When connecting any airbag connector, take care not to damage the airbag wire harness.

    17. Engage the 3 claws to close the 3 clamps as shown in the illustration.
      GTY371777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    18. w/ Manual (SOS) Switch:
      1. Engage the clamp.
    19. w/ Front Center Speaker:
      1. Engage each clamp.
  3. INSTALL INSTRUMENT PANEL SAFETY PAD CAP 
    1. Install 5 new instrument panel safety pad caps.
      GTY573118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *A for LH Side
      *B for RH Side
  4. INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Install the No. 2 instrument panel brace sub-assembly with the bolt and 2 nuts.

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

    2. Install the screw.
    3. Engage each clamp.
    4. Connect each connector.
    5. Connect the earth wire with the bolt.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

  5. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Install the No. 1 instrument panel brace sub-assembly with the bolt and 2 nuts.

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

    2. Install the screw.
    3. Engage each clamp.
    4. Connect the earth wire with the bolt.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

  6. INSTALL COOLER (ROOM TEMP. SENSOR) THERMISTOR 
    1. Connect the aspirator and connector to install the cooler (room temp. sensor) thermistor.
  7. INSTALL NO. 1 CONSOLE BOX DUCT 
    1. Install the No. 1 console box duct with the clip.
  8. INSTALL FLOOR CARPET BRACKET LH 
    1. Install the floor carpet bracket LH with the 2 clips.
  9. INSTALL REAR NO. 1 AIR DUCT 
    1. Engage the 2 claws to install the rear No. 1 air duct.
  10. INSTALL REAR AIR DUCT GUIDE LH 
    1. Engage the 4 claws to install the rear air duct guide LH.
  11. INSTALL FRONT FLOOR CARPET LH 
    1. Engage the 3 fasteners and hook fastener.
    2. Engage the guide to install the front floor carpet LH.
  12. INSTALL FLOOR CARPET BRACKET RH 
    1. Install the floor carpet bracket RH with the 2 clips.
  13. INSTALL REAR NO. 2 AIR DUCT 
    1. Engage the 2 claws to install the rear No. 2 air duct.
  14. INSTALL REAR AIR DUCT GUIDE RH 
    1. Engage the 4 claws to install the rear air duct guide RH.
  15. INSTALL FRONT FLOOR CARPET RH 
    1. Engage the 3 fasteners.
    2. Engage the guide to install the front floor carpet RH.
  16. INSTALL FLOOR CARPET HOOK 
    1. Engage the 6 clamps to install the 6 floor carpet hooks.
    2. Engage the 6 guides.
  17. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY 

    See step  1

  18. INSTALL CERTIFICATION ECU (SMART KEY ECU ASSEMBLY) (w/o ECU Integration Box RH) 

    Refer to PROCEDURE - Step 2

  19. INSTALL ECU INTEGRATION BOX RH (w/ ECU Integration Box RH) 

    Refer to PROCEDURE - Step 3

  20. INSTALL REMOTE ENGINE STARTER ECU WITH BRACKET (w/ Remote Engine Starter System) 

    w/o Glass Breakage Sensor: (Refer to PROCEDURE - Step 2 )

  21. INSTALL GLASS BREAKAGE SENSOR ECU (w/ Glass Breakage Sensor) 

    w/o Remote Engine Starter System: (Refer to PROCEDURE - Step 1 )

  22. INSTALL GLASS BREAKAGE SENSOR ECU WITH REMOTE ENGINE STARTER ECU (w/ Glass Breakage Sensor) 

    w/ Remote Engine Starter System: (Refer to PROCEDURE - Step 3 )

  23. INSTALL WINDSHIELD WIPER RELAY ASSEMBLY (w/ Rain Sensor) 

    Refer to PROCEDURE - Step 1

  24. INSTALL DRIVING SUPPORT ECU ASSEMBLY (w/ Dynamic Radar Cruise Control System) 

    Refer to PROCEDURE - Step 1

  25. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU 

    Refer to PROCEDURE - Step 2

  26. INSTALL SKID CONTROL BUZZER ASSEMBLY (w/ Pre-collision System) 

    Refer to PROCEDURE - Step 1

  27. INSTALL STEERING POST ASSEMBLY 

    (Refer to INSTALLATION [10/2014 - ] )

  28. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY 

    (Refer to INSTALLATION [10/2014 - ] )

  29. INSTALL STEREO COMPONENT AMPLIFIER ASSEMBLY WITH BRACKET (w/ Front Center Speaker) 

    for 9 Speakers: (Refer to PROCEDURE - Step 4 )

    for 11 Speakers: (Refer to PROCEDURE - Step 8 )

  30. INSTALL AUDIO AMPLIFIER COVER (w/ Front Center Speaker) 

    Refer to PROCEDURE - Step 9

  31. INSTALL FRONT SEAT ASSEMBLY LH 

    (Refer to INSTALLATION [10/2014 - ] )

  32. INSTALL DCM (TELEMATICS TRANSCEIVER) WITH BACK-UP BATTERY (w/ Manual (SOS) Switch) 

    Refer to PROCEDURE - Step 4

  33. INSTALL AUDIO AMPLIFIER COVER (w/ Manual (SOS) Switch) 

    Refer to PROCEDURE - Step 5

  34. INSTALL FRONT SEAT ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

  35. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY 
    1. Remove the vinyl tape from the air conditioning tube and accessory assembly.
    2. Sufficiently apply compressor oil to a new O-ring and fitting surface of the air conditioning tube and accessory assembly.

      Compressor Oil

      ND-OIL 8 or equivalent

    3. Install the O-ring to the air conditioning tube and accessory assembly.
    4. Connect the air conditioning tube and accessory assembly.
  36. CONNECT SUCTION HOSE SUB-ASSEMBLY 
    1. Remove the vinyl tape from the suction hose sub-assembly.
    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction hose sub-assembly.

      Compressor Oil

      ND-OIL 8 or equivalent

    3. Install the O-ring to the suction hose sub-assembly.
    4. Connect the suction hose sub-assembly.
    5. Rotate the hook connector as shown in the illustration.
      GTY596915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. 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 HEATER INLET WATER HOSE 
    1. Connect the heater inlet water hose with the marking (Brown) facing up and engage the clip within the area shown in the illustration.
      GTY538840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a View A
      *b Marking (Brown)
      *c Clip Installation Angle (75 to 105°)
      NOTE:

      Do not apply excessive force to the heater inlet water hose.

  38. CONNECT HEATER OUTLET WATER HOSE A 
    1. Connect the heater outlet water hose A with the marking (Pink) facing up and engage the clip within the area shown in the illustration.
      GTY561419Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a View A
      *b Marking (Pink)
      *c Clip Installation Angle (30 to 60°)
      NOTE:

      Do not apply excessive force to the heater outlet water hose A.

  39. INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 10

  40. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    (Refer to INSTALLATION [10/2014 - ] )

  41. ADD ENGINE COOLANT 

    Refer to PROCEDURE - Step 2

  42. INSPECT FOR COOLANT LEAK 

    Refer to PROCEDURE - Step 1

  43. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    See step  2

  44. WARM UP ENGINE 

    See step  3

  45. INSPECT FOR REFRIGERANT LEAK 

    See step  4

  46. INITIALIZE SERVO MOTOR 

    (Refer to INITIALIZATION [10/2014 - ] )

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