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Installation (To 12/2010): Installation

WARNING: This page is about a different car, the 2011 Toyota Avalon. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL AIR CONDITIONING UNIT ASSEMBLY 
    1. Install the conditioning unit assembly to the instrument panel reinforcement assembly with the 2 screws and 3 bolts.
      Fig 1: Installing The Conditioner Unit Assembly With 2 Screws And 3 Bolts
      GTY298554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

      NOTE:

      Tighten the bolts and screws in the order shown in the illustration to install the air conditioner unit assembly.

  2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY 
    1. Driver seat:
      1. Using a "TORX" socket wrench (T40), install the instrument panel reinforcement assembly with the 3 "TORX" bolts.

        Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) 

    2. Passenger seat:
      1. Using a hexagon wrench (12 mm), install the instrument panel reinforcement assembly with the 2 collars.

        Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 

      2. Using a "TORX" socket wrench (T40), install the instrument panel reinforcement assembly with the 2 "TORX" bolts.

        Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

    3. Install the instrument panel reinforcement assembly with air conditioning unit assembly and the 3 bolts and nut.

      NUT 

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

      BOLT A 

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

      Fig 2: Installing Instrument Panel Reinforcement Assembly
      GTY306822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Collar *2 "TORX" bolt
    4. Install the 6 nuts and 4 bolts.
    5. Connect each connector.
    6. Engage each clamp and claw.
  3. INSTALL REAR NO. 2 AIR DUCT 
    1. Engage the 2 claws and install the rear No. 2 air duct.
  4. INSTALL REAR NO. 1 AIR DUCT 
    1. Engage the 2 claws and install the rear No. 1 air duct.
  5. INSTALL FLOOR CARPET BRACKET LH 
    1. Install the floor carpet bracket LH with clip.
  6. INSTALL FLOOR CARPET BRACKET RH 
    1. Install the floor carpet bracket RH with clip.
  7. INSTALL NO. 1 CONSOLE BOX DUCT 
    1. Install the No. 1 console box duct with the clip.
  8. INSTALL NO. 6 HEATER TO REGISTER DUCT ASSEMBLY 
    1. Engage the 4 claws and install the No. 6 heater to register duct assembly.
  9. INSTALL NO. 2 HEATER TO REGISTER DUCT 
    1. Install the No. 2 heater to register duct with the 3 clips.
  10. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY 
    1. Install the instrument panel safety pad subassembly. Refer to INSTALLATION .
  11. INSTALL STEERING COLUMN ASSEMBLY 
    1. Install the steering column assembly. Refer to INSTALLATION .
  12. CONNECT INLET HEATER WATER HOSE 
    1. Using pliers, grip the claws of the clip and slide the clip to connect the inlet heater water hose.
  13. CONNECT OUTLET HEATER WATER HOSE 
    1. Using pliers, grip the claws of the clip and slide the clip to connect the outlet heater water hose.
  14. INSTALL AIR CONDITIONER TUBE AND ACCESSORY 
    1. Remove the attached vinyl tape from the tube.
    2. Sufficiently apply compressor oil to a new O-ring and fitting surface of the air conditioning tube assembly.

      Compressor oil

      ND-OIL 8 or equivalent

    3. Install the O-ring on the air conditioner and accessory.
    4. Install the air conditioner and accessory.
  15. INSTALL SUCTION HOSE SUB-ASSEMBLY 
    1. Remove the attached vinyl tape from hose.
    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction hose sub-assembly.

      Compressor oil

      ND-OIL 8 or equivalent

    3. Install the O-ring on the suction hose sub-assembly.
    4. Move the hook connector in the direction indicated by the arrow in the illustration.
      Fig 3: Identifying Suction Hose Sub-Assembly Bolt and Hook
      GTY299365Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Insert the pipe joint into the fitting hole securely and tighten the bolt.

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

  16. INSTALL COWL TOP PANEL OUTER 
    1. Engage the 12 clips, and install the cowl top panel outer.
  17. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  . Refer to INSTALLATION - Step 1
  18. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 
    1. Install the outer cowl top panel sub-assembly with the 2 nuts and 4 bolts.
  19. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH  . Refer to INSTALLATION - Step 3
  20. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH  . Refer to INSTALLATION - Step 4
  21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  22. ADD ENGINE COOLANT  . Refer to REPLACEMENT - Step 2
  23. CHARGE REFRIGERANT  See step  2
  24. WARM UP ENGINE  See step  3
  25. INSPECT FOR REFRIGERANT LEAK  See step  4
  26. CHECK FOR ENGINE COOLANT LEAKS  . Refer to REPLACEMENT - Step 3
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