LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2020 >> Avalon Limited >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> Air Conditioning System (Service Information) (1 Of 2) >> AIR CONDITIONING UNIT (for HV Model) >> Installation [04/2018 - 08/2019] >> Procedure

Installation [04/2018 - 08/2019]: Procedure

  1. TEMPORARILY INSTALL AIR CONDITIONER UNIT ASSEMBLY 
    1. Engage the 2 claws.
    2. Temporarily install the air conditioner unit assembly to the instrument panel reinforcement assembly with the 3 bolts.
  2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONER UNIT ASSEMBLY 
    NOTE:
    • Be sure to support the air conditioner unit assembly when installing it. Failure to do so may cause the bracket of the air conditioner unit assembly to break.
    • When installing the air conditioner unit assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.
    1. Connect each connector.
      GTY907699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction - -
    2. Engage each clamp.
    3. Temporarily install the instrument panel reinforcement assembly with air conditioner unit assembly as shown in the illustration.
    4. Install the 4 bolts (A).
      GTY933391Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt (A) Bolt (B)
      Nut - -

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

    5. Connect the brake pedal assembly with the bolt (B).

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

    6. Temporarily install the nut.
    7. Install the 3 bolts.

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

    8. Install the 2 hole plugs.
    9. Install a new cooler unit drain hose grommet.
      NOTE:
      • If the drain cooler hose is disconnected from the cooler unit drain hose grommet, make sure to replace the cooler unit drain hose grommet with a new one. Failure to do so may lead to water ingress.
      • Make sure that the entire lip of the cooler unit drain hose grommet is securely engaged to the vehicle body.
      GTY927954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Lip
    10. Connect the drain cooler hose.
    11. GTY945472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install the front floor mat to its original position as shown in the illustration.

    12. Engage each clamp.
      GTY894080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Lock Lever
      Move in this Direction
    13. Temporarily connect the connector and then move the lock lever as shown in the illustration to securely connect the connector.
      NOTE:

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

    14. Check that there is no looseness in the installed parts of the airbag sensor assembly.
    15. Connect the connector.
    16. Engage each clamp.
    17. Connect the connector holder with the 2 nuts.

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

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

      Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

    19. Connect the 2 connectors.
  3. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU 

    Refer to PROCEDURE - Step 3

  4. INSTALL HYBRID VEHICLE CONTROL ECU 

    Refer to PROCEDURE - Step 1

  5. INSTALL NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY 
    1. Install the No. 3 instrument panel to cowl brace sub-assembly with the bolt and nut.

      Bolt 

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Nut 

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    2. Engage each clamp.
  6. INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Install the No. 2 instrument panel brace sub-assembly with the bolt and nut.

      Bolt 

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

      Nut 

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

    2. Temporarily install the screw.

      HINT: 

      Do not fully tighten the screw.

    3. Engage each clamp.
    4. Connect the relay block holder with the bolt (A).

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

      GTY914327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Earth Wire
      *b Relay Block Holder
      Bolt (A)
      Bolt (B)
    5. Connect the earth wire with the bolt (B).

      Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

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

      Bolt 

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

      Nut 

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

    2. Temporarily install the screw.

      HINT: 

      Do not fully tighten the screw.

    3. Engage each clamp.
    4. Connect the 2 earth wires with the 2 bolts.

      Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

  8. INSTALL AIR CONDITIONER UNIT ASSEMBLY 
    1. Tighten the 3 bolts, 2 screws and nut to install the air conditioner unit assembly.
      Fig 1: Air Conditioner Unit Assembly Bolts, Screws And Nut With Tightening Sequence
      GTY917519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt Screw
      Nut - -

      Bolt 

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

      Nut 

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

      NOTE:

      Tighten the bolts, screws and nut in the order shown in the illustration.

  9. INSTALL NO. 3 DASH PANEL INSULATOR PAD 
    1. Install the No. 3 dash panel insulator pad with 2 new clips as shown in the illustration.
      GTY925579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL NO. 1 CONSOLE BOX DUCT 
    1. Install the No. 1 console box duct as shown in the illustration.
      GTY904571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  11. INSTALL FLOOR CARPET BRACKET LH 
    1. Engage the claw as shown in the illustration.
      GTY839800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Install the floor carpet bracket LH with the clip.
  12. INSTALL FLOOR CARPET BRACKET RH 
    1. Engage the claw as shown in the illustration.
      GTY914426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Install the floor carpet bracket RH with the clip.
  13. INSTALL REAR NO. 3 AIR DUCT 
    1. Engage the 2 claws to install the rear No. 3 air duct.
  14. INSTALL REAR NO. 4 AIR DUCT 
    1. Engage the 4 claws to install the rear No. 4 air duct as shown in the illustration.
      GTY937739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Install the front floor carpet assembly to its original position as shown in the illustration.
      GTY925398Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Engage the 2 guides.
    4. Install the 3 front floor carpet clips.
  15. INSTALL REAR NO. 1 AIR DUCT 
    1. Engage the 2 claws to install the rear No. 1 air duct.
  16. INSTALL REAR NO. 2 AIR DUCT 
    1. Engage the 4 claws to install the rear No. 2 air duct as shown in the illustration.
      GTY902410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. GTY945433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install the front floor carpet assembly to its original position as shown in the illustration.

    3. Engage the 2 guides.
    4. Install the 3 front floor carpet clips.
  17. INSTALL ACCELERATOR PEDAL 

    Refer to PROCEDURE - Step 1

  18. INSTALL ACCELERATOR PEDAL PAD 

    Refer to PROCEDURE - Step 2

  19. INSTALL COOLER (ROOM TEMP. SENSOR) THERMISTOR 
    1. Connect the aspirator and connector to install the cooler (room temp. sensor) thermistor.
  20. INSTALL DRIVING SUPPORT ECU ASSEMBLY 

    Refer to PROCEDURE - Step 1

  21. INSTALL NO. 1 CLEARANCE WARNING BUZZER (w/ Intelligent Parking Assist System) 

    Refer to PROCEDURE - Step 1

  22. INSTALL DCM (TELEMATICS TRANSCEIVER) WITH BRACKET 

    Refer to PROCEDURE - Step 6

  23. INSTALL VEHICLE APPROACHING SPEAKER CONTROLLER 

    Refer to PROCEDURE - Step 1

  24. INSTALL ECU INTEGRATION BOX RH 

    Refer to PROCEDURE - Step 2

  25. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY 

    Refer to INSTALLATION [04/2018 -]

  26. INSTALL STEERING COLUMN ASSEMBLY 

    for Manual Tilt and Manual Telescopic Steering Column:

    Refer to INSTALLATION [04/2018 -]

    for Power Tilt and Power Telescopic Steering Column:

    Refer to INSTALLATION [04/2018 -]

  27. INSTALL TRANSMISSION FLOOR SHIFT ASSEMBLY 

    Refer to INSTALLATION [04/2018 -]

  28. INSTALL FRONT SEAT ASSEMBLY LH 

    Refer to INSTALLATION [04/2018 - 08/2020]

  29. INSTALL FRONT SEAT ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

  30. CONNECT AIR CONDITIONING 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 the fitting surface of the air conditioning tube and accessory assembly.

      Compressor Oil

      ND-OIL 11 or equivalent

    3. Install the O-ring to the air conditioning tube and accessory assembly.
      NOTE:

      Keep the O-ring and O-ring fitting surface free of foreign matter.

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

      Compressor Oil

      ND-OIL 11 or equivalent

    3. Install the O-ring to the suction pipe sub-assembly.
      NOTE:

      Keep the O-ring and O-ring fitting surface free of foreign matter.

    4. Connect the suction pipe sub-assembly.
    5. Rotate the hook connector as shown in the illustration.
      GTY945442Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Insert the tube joint into the fitting hole securely and install the bolt.

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

  32. CONNECT INLET HEATER WATER HOSE 
    1. Connect the inlet heater water hose with the marking facing up and engage the clip within the area shown in the illustration.
      NOTE:

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

      GTY903505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      *b Marking (White)
      *c Clip Installation Angle (270°)
  33. CONNECT OUTLET HEATER WATER HOSE 
    1. Connect the outlet heater water hose with the marking facing up and engage the clip within the area shown in the illustration.
      GTY936197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      *b Marking (Green)
      *c Clip Installation Angle (270°)
      NOTE:

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

  34. INSTALL FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  35. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to INSTALLATION [04/2018 -]

  36. ADD ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 2

  37. INSPECT FOR COOLANT LEAK (for Engine) 

    Refer to PROCEDURE - Step 1

  38. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    See step  2

  39. WARM UP COMPRESSOR 

    See step  4

  40. INSPECT FOR REFRIGERANT LEAK 

    See step  5

scientia non olet · About LEMON Manuals