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Home >> Toyota >> 2020 >> Avalon Limited >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> Air Conditioning System (Service Information) (2 Of 2) >> AIR CONDITIONING UNIT (for Gasoline Model) >> Installation [08/2021 -] >> Procedure

Installation [08/2021 -]: Procedure

  1. TEMPORARILY INSTALL AIR CONDITIONER UNIT ASSEMBLY 

    Refer to PROCEDURE - Step 1

  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 connector.
  3. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU 

    Refer to PROCEDURE - Step 3

  4. INSTALL 4WD ECU ASSEMBLY (for AWD) 

    Refer to PROCEDURE - Step 1

  5. INSTALL NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  6. INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  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 earth wire with the bolt.

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

  8. INSTALL AIR CONDITIONER UNIT ASSEMBLY 

    Refer to PROCEDURE - Step 8

  9. INSTALL NO. 3 DASH PANEL INSULATOR PAD 

    Refer to PROCEDURE - Step 9

  10. INSTALL NO. 1 CONSOLE BOX DUCT 

    Refer to PROCEDURE - Step 10

  11. INSTALL FLOOR CARPET BRACKET LH 

    Refer to PROCEDURE - Step 11

  12. INSTALL FLOOR CARPET BRACKET RH 

    Refer to PROCEDURE - Step 12

  13. INSTALL REAR NO. 3 AIR DUCT 

    Refer to PROCEDURE - Step 13

  14. INSTALL REAR NO. 4 AIR DUCT 

    Refer to PROCEDURE - Step 14

  15. INSTALL REAR NO. 1 AIR DUCT 

    Refer to PROCEDURE - Step 15

  16. INSTALL REAR NO. 2 AIR DUCT 

    Refer to PROCEDURE - Step 16

  17. INSTALL ACCELERATOR PEDAL 

    for 2GR-FKS:

    Refer to PROCEDURE - Step 1

    for A25A-FKS:

    Refer to PROCEDURE - Step 1

  18. INSTALL ACCELERATOR PEDAL PAD 

    for 2GR-FKS:

    Refer to PROCEDURE - Step 2

    for A25A-FKS:

    Refer to PROCEDURE - Step 2

  19. INSTALL COOLER (ROOM TEMP. SENSOR) THERMISTOR 

    Refer to PROCEDURE - Step 19

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

    Refer to PROCEDURE - Step 1

  21. INSTALL DCM (TELEMATICS TRANSCEIVER) WITH BRACKET 

    Refer to PROCEDURE - Step 8

  22. INSTALL STEREO COMPONENT EQUALIZER ASSEMBLY (w/ Active Noise Control System) 

    Refer to PROCEDURE - Step 1

  23. INSTALL ECU INTEGRATION BOX RH 

    Refer to PROCEDURE - Step 2

  24. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY 

    Refer to INSTALLATION [04/2018 -]

  25. 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 -]

  26. INSTALL TRANSMISSION FLOOR SHIFT ASSEMBLY 

    Refer to INSTALLATION [04/2018 -]

  27. INSTALL FRONT SEAT ASSEMBLY LH 

    Refer to INSTALLATION [08/2020 -]

  28. INSTALL FRONT SEAT ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

  29. CONNECT NO. 2 AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (for 2GR-FKS) 
    1. Remove the vinyl tape from the No. 2 air conditioning tube and accessory assembly.
    2. Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces of the No. 2 air conditioning tube and accessory assembly.

      Compressor Oil

      ND-OIL 12 or equivalent

    3. Install the 2 O-rings to the No. 2 air conditioning tube and accessory assembly.
      NOTE:

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

    4. Connect the No. 2 air conditioning tube and accessory assembly.
    5. Rotate the hook connector as shown in the illustration.
      GTY919983Courtesy 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) 

  30. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (for A25A-FKS) 
    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 12 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 from foreign matter.

    4. Connect the air conditioning tube and accessory assembly.
  31. CONNECT SUCTION PIPE SUB-ASSEMBLY (for A25A-FKS) 
    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 12 or equivalent

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

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

    4. Connect the suction pipe sub-assembly.
    5. Rotate the hook connector as shown in the illustration.
      GTY989199Courtesy 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 (for 2GR-FKS) 
    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.

      GTY869213Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      *b Marking (Yellow)
      *c Clip Installation Angle (270°)
  33. CONNECT INLET HEATER WATER HOSE (for A25A-FKS) 
    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.

      GTY989331Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      *b Marking (White)
      *c Clip Installation Angle (270°)
  34. CONNECT OUTLET HEATER WATER HOSE (for 2GR-FKS) 
    1. Connect the outlet heater water hose with the marking facing up and engage the clip within the area shown in the illustration.
      GTY874287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      *b Marking (Purple)
      *c Clip Installation Angle (270°)
      NOTE:

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

  35. CONNECT OUTLET HEATER WATER HOSE (for A25A-FKS) 
    1. Connect the outlet heater water hose with the marking facing up and engage the clip within the area shown in the illustration.
      GTY989990Courtesy 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.

  36. INSTALL FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  37. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to INSTALLATION [04/2018 -]

  38. ADD ENGINE COOLANT 

    for 2GR-FKS:

    Refer to PROCEDURE - Step 2

    for A25A-FKS:

    Refer to PROCEDURE - Step 2

  39. INSPECT FOR COOLANT LEAK 

    for 2GR-FKS:

    Refer to PROCEDURE - Step 1

    for A25A-FKS:

    Refer to PROCEDURE - Step 1

  40. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 2

  41. WARM UP ENGINE 

    Refer to PROCEDURE - Step 3

  42. INSPECT FOR REFRIGERANT LEAK 

    Refer to PROCEDURE - Step 5

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