Last Modified: 08-21-2023 6.11:8.1.0 Doc ID: RM100000001JUAD
Model Year Start: 2020 Model: Avalon HV Prod Date Range: [08/2019 -           ]
Title: HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT (for HV Model): DISASSEMBLY; 2020 - 2022 MY Avalon HV [08/2019 -        ]

DISASSEMBLY

PROCEDURE

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

(a) Remove the 2 screws.

(b) Disengage the 6 claws to remove the No. 4 heater to register duct sub-assembly.

2. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY

(a) Disengage the 4 claws to remove the No. 2 air duct sub-assembly.

3. REMOVE NO. 2 AIR DUCT

(a) Remove the screw.

*a

View A

Front

(b) Disengage the 3 claws to remove the No. 2 air duct.

NOTICE:

Be careful not to deform or damage the lower heater case of the air conditioner unit assembly when removing the No. 2 air duct.

4. REMOVE ASPIRATOR

(a) Disengage the guide and 2 claws to remove the aspirator.

5. REMOVE BLOWER ASSEMBLY

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6. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY

(a) Disconnect the connector.

Remove in this Direction

(b) Remove the screw.

(c) Disengage the guide to remove the air conditioning amplifier assembly as shown in the illustration.

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

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9. REMOVE DRAIN COOLER HOSE

(a) Remove the drain cooler hose.

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

(a) Remove the 3 screws and No. 1 air conditioning radiator damper servo sub-assembly.

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

(a) Remove the 2 screws and No. 2 air conditioning radiator damper servo sub-assembly.

12. REMOVE NO. 3 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY

(a) Remove the 2 screws and No. 3 air conditioning radiator damper servo sub-assembly.

13. REMOVE HEATER PIPE GROMMET

(a) Remove the heater pipe grommet.

14. REMOVE HEATER CLAMP

(a) Disengage the 3 claws to remove the heater clamp.

15. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY

Remove in this Direction

(a) Remove the heater radiator unit sub-assembly as shown in the illustration.

NOTICE:

Prepare a drain pan or cloth in case the coolant leaks.

16. REMOVE COOLING UNIT PARTS

(a) Remove the cooling unit parts.

17. REMOVE COOLER EXPANSION VALVE

(a) Using a 4 mm hexagon socket wrench, remove the 2 hexagon bolts and cooler expansion valve.

(b) Remove the 2 O-rings from the No. 1 cooler evaporator sub-assembly.

18. 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.

(c) Disengage the clamp.

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

NOTICE:

When the No. 1 cooler evaporator sub-assembly is removed, make sure to install a new one. The No. 1 cooler evaporator sub-assembly cannot be reused.

19. REMOVE NO. 1 COOLER THERMISTOR

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