Toyota Avalon (XX50): Air Conditioning Unit(for 2gr-fks)

Toyota Avalon (XX50) 2019-2022 Service & Repair Manual / Vehicle Interior / Heating / Air Conditioning / Air Conditioning Unit(for 2gr-fks)

Components

COMPONENTS

ILLUSTRATION

*1	FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY	-	-
	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": Nm (kgfcm, ft.*lbf)		Nm (kgfcm, ft.*lbf): Specified torque

ILLUSTRATION

*1	INLET HEATER WATER HOSE	*2	NO. 2 AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY
*3	OUTLET HEATER WATER HOSE	*4	O-RING
	Nm (kgfcm, ft.*lbf): Specified torque	●	Non-reusable part
	Compressor oil ND-OIL 12 or equivalent	-	-

ILLUSTRATION

*A	w/ Intelligent Parking Assist System	*B	w/ Active Noise Control System
*1	COOLER (ROOM TEMP. SENSOR) THERMISTOR	*2	DCM (TELEMATICS TRANSCEIVER) WITH BRACKET
*3	DRIVING SUPPORT ECU ASSEMBLY	*4	ECU INTEGRATION BOX RH
*5	NO. 1 CLEARANCE WARNING BUZZER	*6	STEREO COMPONENT EQUALIZER ASSEMBLY
	Nm (kgfcm, ft.*lbf): Specified torque	-	-

ILLUSTRATION

*1	ACCELERATOR PEDAL	*2	ACCELERATOR PEDAL PAD
*3	FLOOR CARPET BRACKET LH	*4	FLOOR CARPET BRACKET RH
*5	NO. 1 CONSOLE BOX DUCT	*6	NO. 3 DASH PANEL INSULATOR PAD
*7	REAR NO. 1 AIR DUCT	*8	REAR NO. 2 AIR DUCT
*9	REAR NO. 3 AIR DUCT	*10	REAR NO. 4 AIR DUCT
*11	FRONT FLOOR CARPET ASSEMBLY	*12	FRONT FLOOR CARPET CLIP
*13	CLIP	-	-
	Nm (kgfcm, ft.*lbf): Specified torque	●	Non-reusable part

ILLUSTRATION

*1	INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU	*2	NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY
*3	NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY	*4	NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY
*5	RELAY BLOCK HOLDER	*6	EARTH WIRE
	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": Nm (kgfcm, ft.*lbf)		Nm (kgfcm, ft.*lbf): Specified torque

ILLUSTRATION

*1	AIR CONDITIONER UNIT ASSEMBLY	*2	INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONER UNIT ASSEMBLY
*3	INSTRUMENT PANEL REINFORCEMENT ASSEMBLY	*4	FRONT FLOOR MAT
*5	CONNECTOR HOLDER	*6	HOLE PLUG
*7	EARTH WIRE	*8	COOLER UNIT DRAIN HOSE GROMMET
	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": Nm (kgfcm, ft.*lbf)		Nm (kgfcm, ft.*lbf): Specified torque
●	Non-reusable part	-	-

ILLUSTRATION

*1	AIR CONDITIONING AMPLIFIER ASSEMBLY	*2	AIR CONDITIONING HARNESS ASSEMBLY
*3	ASPIRATOR	*4	BLOWER ASSEMBLY
*5	NO. 2 AIR DUCT	*6	NO. 2 AIR DUCT SUB-ASSEMBLY
*7	NO. 4 HEATER TO REGISTER DUCT SUB-ASSEMBLY	*8	AIR CONDITIONING RADIATOR ASSEMBLY
●	Non-reusable part	-	-

ILLUSTRATION

*1	COOLER EXPANSION VALVE	*2	COOLING UNIT PARTS
*3	DRAIN COOLER HOSE	*4	HEATER CLAMP
*5	HEATER COVER	*6	HEATER PIPE GROMMET
*7	HEATER RADIATOR UNIT SUB-ASSEMBLY	*8	NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY
*9	NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY	*10	NO. 1 COOLER THERMISTOR
*11	NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY	*12	UPPER HEATER CASE
*13	LOWER HEATER CASE	*14	O-RING
	Nm (kgfcm, ft.*lbf): Specified torque	●	Non-reusable part
	Compressor oil ND-OIL 12 or equivalent	-	-

Disassembly

DISASSEMBLY

PROCEDURE

1. REMOVE NO. 4 HEATER TO REGISTER DUCT SUB-ASSEMBLY

Click here

2. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY

Click here

3. REMOVE NO. 2 AIR DUCT

Click here

4. REMOVE ASPIRATOR

Click here

5. REMOVE BLOWER ASSEMBLY

Click here

6. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY

Click here

7. REMOVE AIR CONDITIONING HARNESS ASSEMBLY

(a) Disconnect each connector.

(b) Disengage each clamp to remove the air conditioning harness assembly.

8. REMOVE HEATER COVER

(a) Remove the screw.

Remove in this Direction

(b) Remove the heater cover as shown in the illustration.

9. REMOVE DRAIN COOLER HOSE

Click here

10. REMOVE NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY

Click here

11. REMOVE NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY

Click here

12. REMOVE HEATER PIPE GROMMET

Click here

13. REMOVE HEATER CLAMP

Click here

14. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY

Click here

15. REMOVE COOLING UNIT PARTS

Click here

16. REMOVE COOLER EXPANSION VALVE

Click here

17. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY

(a) Remove the 2 screws.

(b) Disengage the 10 claws to remove the upper heater case with No. 1 cooler evaporator sub-assembly from the lower heater case.

(d) Remove the No. 1 cooler evaporator sub-assembly with No. 1 cooler thermistor from the upper heater case.

18. REMOVE NO. 1 COOLER THERMISTOR

Click here

Installation

INSTALLATION

PROCEDURE

1. TEMPORARILY INSTALL AIR CONDITIONER UNIT ASSEMBLY

Click here

2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONER UNIT ASSEMBLY

NOTICE:

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.

(a) Connect each connector.

Install in this Direction

(b) Engage each clamp.

(c) Temporarily install the instrument panel reinforcement assembly with air conditioner unit assembly as shown in the illustration.

(d) Install the 4 bolts (A).

	Bolt (A)		Bolt (B)
	Nut	-	-

Torque:

25 N·m {255 kgf·cm, 18 ft·lbf}

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

Torque:

15 N·m {153 kgf·cm, 11 ft·lbf}

(f) Temporarily install the nut.

(g) Install the 3 bolts.

Torque:

25 N·m {255 kgf·cm, 18 ft·lbf}

(h) Install the 2 hole plugs.

(i) Install a new cooler unit drain hose grommet.

NOTICE:

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.

Lip

(j) Connect the drain cooler hose.

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

(l) Engage each clamp.

*a	Lock Lever
	Move in this Direction

(m) Temporarily connect the connector and then move the lock lever as shown in the illustration to securely connect the connector.

NOTICE:

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

(n) Check that there is no looseness in the installed parts of the airbag sensor assembly.

(o) Connect the connector.

(p) Engage each clamp.

(q) Connect the connector holder with the 2 nuts.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(r) Connect the 3 earth wires with the 3 bolts.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

(s) Connect the connector.

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

Click here

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

Click here

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

Click here

6. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

(a) Install the No. 1 instrument panel brace sub-assembly with the bolt and nut.

Torque:

Bolt :

20 N·m {204 kgf·cm, 15 ft·lbf}

Nut :

18 N·m {184 kgf·cm, 13 ft·lbf}

(b) Temporarily install the screw.

HINT:

Do not fully tighten the screw.

(d) Connect the earth wire with the bolt.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

7. INSTALL AIR CONDITIONER UNIT ASSEMBLY

Click here

8. INSTALL NO. 3 DASH PANEL INSULATOR PAD

Click here

9. INSTALL NO. 1 CONSOLE BOX DUCT

Click here

10. INSTALL FLOOR CARPET BRACKET LH

Click here

11. INSTALL FLOOR CARPET BRACKET RH

Click here

12. INSTALL REAR NO. 3 AIR DUCT

Click here

13. INSTALL REAR NO. 4 AIR DUCT

Click here

14. INSTALL REAR NO. 1 AIR DUCT

Click here

15. INSTALL REAR NO. 2 AIR DUCT

Click here

16. INSTALL ACCELERATOR PEDAL

Click here

17. INSTALL ACCELERATOR PEDAL PAD

Click here

18. INSTALL COOLER (ROOM TEMP. SENSOR) THERMISTOR

Click here

19. INSTALL DRIVING SUPPORT ECU ASSEMBLY

Click here

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

Click here

21. INSTALL DCM (TELEMATICS TRANSCEIVER) WITH BRACKET

Click here

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

Click here

23. INSTALL ECU INTEGRATION BOX RH

Click here

24. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

Click here

25. INSTALL STEERING COLUMN ASSEMBLY

for Manual Tilt and Manual Telescopic Steering Column:

Click here

for Power Tilt and Power Telescopic Steering Column:

Click here

26. INSTALL TRANSMISSION FLOOR SHIFT ASSEMBLY

Click here

27. INSTALL FRONT SEAT ASSEMBLY LH

Click here

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

(a) Remove the vinyl tape from the No. 2 air conditioning tube and accessory assembly.

(b) 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

NOTICE:

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

(d) Connect the No. 2 air conditioning tube and accessory assembly.

(e) Rotate the hook connector as shown in the illustration.

(f) 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 INLET HEATER WATER HOSE

(a) Connect the inlet heater water hose with the marking facing up and engage the clip within the area shown in the illustration.

NOTICE:

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

*a	View A
*b	Marking (Yellow)
*c	Clip Installation Angle (270°)

31. CONNECT OUTLET HEATER WATER HOSE

(a) Connect the outlet heater water hose with the marking facing up and engage the clip within the area shown in the illustration.

NOTICE:

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

*a	View A
*b	Marking (Purple)
*c	Clip Installation Angle (270°)

32. INSTALL FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY

Click here

33. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here

34. ADD ENGINE COOLANT

Click here

35. INSPECT FOR COOLANT LEAK

Click here

36. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

Click here

37. WARM UP ENGINE

Click here

38. INSPECT FOR REFRIGERANT LEAK

Click here

Reassembly

REASSEMBLY

PROCEDURE

1. INSTALL NO. 1 COOLER THERMISTOR

Click here

2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY

(a) Install the No. 1 cooler evaporator sub-assembly with No. 1 cooler thermistor to the upper heater case.

(b) Engage the clamp.

(c) Engage the 10 claws to install the upper heater case with No. 1 cooler evaporator sub-assembly to the lower heater case.

(d) Install the 2 screws.

3. INSTALL COOLER EXPANSION VALVE

(a) Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces of the No. 1 cooler evaporator sub-assembly.

Compressor Oil:

ND-OIL 12 or equivalent

(b) Install the 2 O-rings to the No. 1 cooler evaporator sub-assembly.

NOTICE:

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

Torque:

3.5 N·m {36 kgf·cm, 31 in·lbf}

4. INSTALL COOLING UNIT PARTS

Click here

5. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY

Click here

6. INSTALL HEATER CLAMP

Click here

7. INSTALL HEATER PIPE GROMMET

Click here

8. INSTALL NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY

Click here

9. INSTALL NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY

Click here

10. INSTALL DRAIN COOLER HOSE

Click here

11. INSTALL HEATER COVER

Install in this Direction

(a) Install the heater cover as shown in the illustration.

(b) Install the screw.

12. INSTALL AIR CONDITIONING HARNESS ASSEMBLY

(a) Engage each clamp.

(b) Connect each connector to install the air conditioning harness assembly.

13. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY

Click here

14. INSTALL BLOWER ASSEMBLY

Click here

15. INSTALL ASPIRATOR

Click here

16. INSTALL NO. 2 AIR DUCT

Click here

17. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY

Click here

18. INSTALL NO. 4 HEATER TO REGISTER DUCT SUB-ASSEMBLY

Click here

Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during air conditioning unit removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
*: When performing learning using the Techstream. Click here
Disconnect cable from negative battery terminal	Perform steering sensor zero point calibration	Lane Departure Alert System (w/ Steering Control)
		Pre-collision System
		Intelligent Clearance Sonar System*
		Lighting System (for Gasoline Model with Cornering Light)
	Memorize steering angle neutral point	Parking Assist Monitor System
	Memorize steering angle neutral point	Panoramic View Monitor System
Steering sensor	Steering angle zero point learning (Initialize intelligent clearance sonar system)	Intelligent Clearance Sonar System Intuitive Parking Assist System
	Steering angle zero point learning (Initialize parking assist monitor system) Steering angle setting	Parking Assist Monitor System	for Initialization for Calibration
	Steering angle zero point learning (Initialize panoramic view monitor system)	Panoramic View Monitor System	for Initialization for Calibration
Front passenger seat	Zero point calibration (Occupant classification system)	Occupant classification system Passenger airbag ON/OFF indicator Airbag system (Front passenger side) Seat belt warning system (Front passenger)

CAUTION:

Some of these service operations affect the SRS airbag system. Read the precautionary notices concerning the SRS airbag system before servicing.

Click here

PROCEDURE

1. PRECAUTION

NOTICE:

Make sure to select face mode before disconnecting the cable from the negative (-) battery terminal.

2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

Click here

3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here

4. REMOVE FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY

Click here

5. DISCONNECT OUTLET HEATER WATER HOSE

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

NOTICE:

Do not apply excessive force to the outlet heater water hose.
Prepare a drain pan or cloth in case the coolant leaks.

6. DISCONNECT INLET HEATER WATER HOSE

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

NOTICE:

Do not apply excessive force to the inlet heater water hose.
Prepare a drain pan or cloth in case the coolant leaks.

7. DISCONNECT NO. 2 AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY

(a) Remove the bolt and rotate the hook connector as shown in the illustration.

(b) Disconnect the No. 2 air conditioning tube and accessory assembly.

NOTICE:

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

8. REMOVE FRONT SEAT ASSEMBLY LH

Click here

9. REMOVE FRONT SEAT ASSEMBLY RH

HINT:

Use the same procedure as for the LH side.

10. REMOVE TRANSMISSION FLOOR SHIFT ASSEMBLY

Click here

11. REMOVE STEERING COLUMN ASSEMBLY

for Manual Tilt and Manual Telescopic Steering Column:

Click here

for Power Tilt and Power Telescopic Steering Column:

Click here

12. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

Click here

13. REMOVE ECU INTEGRATION BOX RH

Click here

14. REMOVE STEREO COMPONENT EQUALIZER ASSEMBLY (w/ Active Noise Control System)

Click here

15. REMOVE DCM (TELEMATICS TRANSCEIVER) WITH BRACKET

Click here

16. REMOVE NO. 1 CLEARANCE WARNING BUZZER (w/ Intelligent Parking Assist System)

Click here

17. REMOVE DRIVING SUPPORT ECU ASSEMBLY

Click here

18. REMOVE COOLER (ROOM TEMP. SENSOR) THERMISTOR

Click here

19. REMOVE ACCELERATOR PEDAL PAD

Click here

20. REMOVE ACCELERATOR PEDAL

Click here

21. REMOVE REAR NO. 2 AIR DUCT

Click here

22. REMOVE REAR NO. 1 AIR DUCT

Click here

23. REMOVE REAR NO. 4 AIR DUCT

Click here

24. REMOVE REAR NO. 3 AIR DUCT

Click here

25. REMOVE FLOOR CARPET BRACKET RH

Click here

26. REMOVE FLOOR CARPET BRACKET LH

Click here

27. REMOVE NO. 1 CONSOLE BOX DUCT

Click here

28. REMOVE NO. 3 DASH PANEL INSULATOR PAD

Click here

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

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

*a	Earth Wire

(b) Disengage each clamp.

	Bolt
	Screw
	Nut

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

Click here

31. REMOVE NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY

Click here

32. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU

Click here

33. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONER UNIT ASSEMBLY

NOTICE:

Be sure to support the air conditioner unit assembly when removing it. Failure to do so may cause the bracket of the air conditioner unit assembly to break.
When disassembling the air conditioner unit assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.

(a) Disconnect the connector.

*a	Earth Wire	*b	Connector Holder
	Connector		Bolt
	Nut	-	-

(b) Remove the 3 bolts and disconnect the 3 earth wires.

(d) Disengage each clamp.

(e) Push down the part (A) in the direction indicated by the arrow (1), to release the lock, and then move the lock lever in the direction indicated by the arrow (2) shown in the illustration to disconnect the connector.

	Release (1)
	Move in this Direction (2)

NOTICE:

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

(f) Disconnect the connector.

(g) Disengage each clamp to separate the instrument panel wire.

(h) Turn back the front floor mat as shown in the illustration.

(i) Disconnect the drain cooler hose.

NOTICE:

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.

*1	Cooler Unit Drain Hose Grommet

(j) Remove the cooler unit drain hose grommet.

(k) Remove the 2 hole plugs.

(l) Remove the 3 bolts.

(m) Remove the 4 bolts (A).

	Bolt (A)		Bolt (B)
	Nut	-	-

(n) Remove the bolt (B) and disconnect the brake pedal assembly.

(o) Remove the nut.

(p) Disengage each clamp.

Remove in this Direction

(q) Disconnect each connector.

(r) Remove the instrument panel reinforcement assembly with air conditioner unit assembly as shown in the illustration.

34. REMOVE AIR CONDITIONER UNIT ASSEMBLY

Click here

Air Conditioning System(for Gasoline Model)

Ambient Temperature Sensor(for 2gr-fks)

See More:

Toyota Avalon (XX50) 2019-2022 Service & Repair Manual > Door Lock: Door Control Receiver
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