HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT (for Gasoline Model): REMOVAL; 2021 MY Avalon [08/2020

Last Modified: 08-21-2023	6.11:8.1.0	Doc ID: RM100000001QM08
Model Year Start: 2021	Model: Avalon	Prod Date Range: [08/2020 - 08/2021]
Title: HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT (for Gasoline Model): REMOVAL; 2021 MY Avalon [08/2020 - 08/2021]

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

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3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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4. REMOVE FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY

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5. DISCONNECT OUTLET HEATER WATER HOSE (for 2GR-FKS)

(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 OUTLET HEATER WATER HOSE (for A25A-FKS)

(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.

7. DISCONNECT INLET HEATER WATER HOSE (for 2GR-FKS)

(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.

8. DISCONNECT INLET HEATER WATER HOSE (for A25A-FKS)

(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.

9. DISCONNECT NO. 2 AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (for 2GR-FKS)

(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.

10. DISCONNECT SUCTION PIPE SUB-ASSEMBLY (for A25A-FKS)

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

(b) Disconnect the suction pipe sub-assembly.

NOTICE:

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

11. DISCONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (for A25A-FKS)

(a) Disconnect the air conditioning tube and accessory assembly.

(b) Remove the O-ring from the 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.

12. REMOVE FRONT SEAT ASSEMBLY LH

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13. REMOVE FRONT SEAT ASSEMBLY RH

HINT:

Use the same procedure as for the LH side.

14. REMOVE TRANSMISSION FLOOR SHIFT ASSEMBLY

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15. REMOVE STEERING COLUMN ASSEMBLY

for Manual Tilt and Manual Telescopic Steering Column:

Click here

for Power Tilt and Power Telescopic Steering Column:

Click here

16. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

Click here

17. REMOVE ECU INTEGRATION BOX RH

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

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19. REMOVE DCM (TELEMATICS TRANSCEIVER) WITH BRACKET

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

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21. REMOVE DRIVING SUPPORT ECU ASSEMBLY

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22. REMOVE COOLER (ROOM TEMP. SENSOR) THERMISTOR

Click here

23. REMOVE ACCELERATOR PEDAL PAD

for 2GR-FKS:

Click here

for A25A-FKS:

Click here

24. REMOVE ACCELERATOR PEDAL

for 2GR-FKS:

Click here

for A25A-FKS:

Click here

25. REMOVE REAR NO. 2 AIR DUCT

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26. REMOVE REAR NO. 1 AIR DUCT

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27. REMOVE REAR NO. 4 AIR DUCT

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28. REMOVE REAR NO. 3 AIR DUCT

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29. REMOVE FLOOR CARPET BRACKET RH

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30. REMOVE FLOOR CARPET BRACKET LH

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31. REMOVE NO. 1 CONSOLE BOX DUCT

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32. REMOVE NO. 3 DASH PANEL INSULATOR PAD

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33. 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

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

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

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36. REMOVE 4WD ECU ASSEMBLY (for AWD)

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

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38. 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.

39. REMOVE AIR CONDITIONER UNIT ASSEMBLY

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