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

Last Modified: 08-21-2023	6.11:8.1.0	Doc ID: RM100000001QM0D
Model Year Start: 2021	Model: Avalon	Prod Date Range: [08/2020 - 08/2021]
Title: HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT (for Gasoline Model): INSTALLATION; 2021 MY Avalon [08/2020 - 08/2021]

INSTALLATION

PROCEDURE

1. TEMPORARILY INSTALL AIR CONDITIONER UNIT ASSEMBLY

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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

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4. INSTALL 4WD ECU ASSEMBLY (for AWD)

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

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

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7. 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}

8. INSTALL AIR CONDITIONER UNIT ASSEMBLY

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9. INSTALL NO. 3 DASH PANEL INSULATOR PAD

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10. INSTALL NO. 1 CONSOLE BOX DUCT

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11. INSTALL FLOOR CARPET BRACKET LH

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12. INSTALL FLOOR CARPET BRACKET RH

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13. INSTALL REAR NO. 3 AIR DUCT

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14. INSTALL REAR NO. 4 AIR DUCT

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15. INSTALL REAR NO. 1 AIR DUCT

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16. INSTALL REAR NO. 2 AIR DUCT

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17. INSTALL ACCELERATOR PEDAL

for 2GR-FKS:

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for A25A-FKS:

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18. INSTALL ACCELERATOR PEDAL PAD

for 2GR-FKS:

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for A25A-FKS:

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19. INSTALL COOLER (ROOM TEMP. SENSOR) THERMISTOR

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20. INSTALL DRIVING SUPPORT ECU ASSEMBLY

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

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22. INSTALL DCM (TELEMATICS TRANSCEIVER) WITH BRACKET

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

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24. INSTALL ECU INTEGRATION BOX RH

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25. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

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26. INSTALL STEERING COLUMN ASSEMBLY

for Manual Tilt and Manual Telescopic Steering Column:

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for Power Tilt and Power Telescopic Steering Column:

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27. INSTALL TRANSMISSION FLOOR SHIFT ASSEMBLY

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28. INSTALL FRONT SEAT ASSEMBLY LH

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29. INSTALL FRONT SEAT ASSEMBLY RH

HINT:

Use the same procedure as for the LH side.

30. CONNECT NO. 2 AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (for 2GR-FKS)

(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}

31. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (for A25A-FKS)

(a) Remove the vinyl tape from the air conditioning tube and accessory assembly.

(b) 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

NOTICE:

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

(d) Connect the air conditioning tube and accessory assembly.

32. CONNECT SUCTION PIPE SUB-ASSEMBLY (for A25A-FKS)

(a) Remove the vinyl tape from the suction pipe sub-assembly.

(b) 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

NOTICE:

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

(d) Connect the suction pipe sub-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}

33. CONNECT INLET HEATER WATER HOSE (for 2GR-FKS)

(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°)

34. CONNECT INLET HEATER WATER HOSE (for A25A-FKS)

(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 (White)
*c	Clip Installation Angle (270°)

35. CONNECT OUTLET HEATER WATER HOSE (for 2GR-FKS)

(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°)

36. CONNECT OUTLET HEATER WATER HOSE (for A25A-FKS)

(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 (Green)
*c	Clip Installation Angle (270°)

37. INSTALL FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY

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38. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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39. ADD ENGINE COOLANT

for 2GR-FKS:

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for A25A-FKS:

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40. INSPECT FOR COOLANT LEAK

for 2GR-FKS:

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for A25A-FKS:

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41. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

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42. WARM UP ENGINE

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43. INSPECT FOR REFRIGERANT LEAK

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