Toyota Avalon, Camry, Camry Solara 2001-06

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    CAUTION
    After disconnecting the negative battery cable, wait for at least 1 1 / 2 minutes for the SRS to deplete its energy.

  4.  
  5. Drain the cooling system into a clean container for reuse.
  6.  
  7. Remove the air bag module and the steering wheel by performing the following procedure:

    Place the front wheels in the straight-ahead position.
     
    At both sides of the steering wheel, remove the screw covers.
     
    Using a Torx socket, loosen the 2 air bag module-to-steering wheel Torx screws until the circumference ring catches on the screw case.
     
    Carefully, remove the air bag module and disconnect the electrical connector.
     
    Remove the steering wheel nut.
     
    Using a steering wheel puller, press the steering wheel from the steering column.
     

  8.  
  9. Remove the instrument panel by performing the following procedure:

    Remove the front pillar garnishes and the door scuff plates.
     
    Remove the hood lock release lever and the cowl side trims.
     
    Remove the steering column covers and the combination switch.
     
    Remove the lower finish panel assembly and the instrument panel finish lower left side panel.
     
    Remove the fuse box bolt and the No. 2 heater-to-register duct.
     
    Remove the parking brake release lever and the No. 2 undercover.
     
    Remove the lower No. 2 finish panel.
     
    If equipped with a column shifter, disconnect the shift control cable from the shift lever housing; then, disconnect the shift control cable from the steering column cable bracket.
     
    Matchmark the steering column shaft and the control valve shaft.
     
    Remove the steering column shaft-to-intermediate shaft bolt.
     
    Remove the steering column-to-instrument panel nuts and remove the steering column assembly.
     
    Inside the glove compartment, pry out the glove compartment door finish plate.
     
    Pull out the air bag electrical connector and disconnect it.
     
    Remove the 3 glove compartment door-to-instrument panel nuts and the door.
     
    Remove the 4 glove compartment-to-instrument panel screws and the glove compartment; then, disconnect the glove box light connector.
     
    Remove the passenger-s side air bag module-to-instrument panel 2 bolts and 4 nuts. Carefully, remove the air bag module from the instrument panel.
     
    Remove the center cluster finish panel and the radio.
     
    Remove the heater control assembly.
     
    If equipped with a floor shifter, remove the upper console panel, the rear console box and the front console box.
     
    If equipped with a column shifter, remove the finish panel.
     
    Pry out the cluster finish panel.
     
    Remove the 6 cluster finish panel screws, the cluster finish panel assembly.
     
    Remove the 4 combination meter screws and the combination meter.
     
    Disconnect instrument panel electrical connectors.
     
    Remove the instrument panel-to-chassis nuts/bolts and the remove the instrument panel.
     

  10.  
  11. Remove the instrument panels No. 2 brace.
  12.  
  13. Disconnect the heater hoses from the heater core.
  14.  
  15. Remove the 2 heater pipes-to-heater core screws and clips; then, disconnect the heater pipes from the heater core.
  16.  
  17. Remove the heater core O-rings and discard them.
  18.  
  19. Remove the heater core from the heater housing.

    Click image to see an enlarged view

    Fig. Exploded view of the air bag module, the steering wheel, the floor shift steering column and related components-2002-04 Avalon



    Click image to see an enlarged view

    Fig. Exploded view of the air bag module, the steering wheel, the column shift steering column and related components-2002-04 Avalon



    Click image to see an enlarged view

    Fig. Releasing the air bag module-to-steering wheel screws-2002-04 Avalon



    Click image to see an enlarged view

    Fig. Disconnecting and positioning the air bag module-2002-04 Avalon



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel and related components-2002-04 Avalon



    Click image to see an enlarged view

    Fig. Exploded view of the wiring harness, ventilation system and related components-2002-04 Avalon



    Click image to see an enlarged view

    Fig. View of the heater/air conditioning assembly and related components-2002-04 Avalon



    Click image to see an enlarged view

    Fig. Exploded view of the evaporator housing, heater housing, heater core and related components-2002-04 Avalon

  20.  

To install:

  1. Install the heater core to the heater housing.
  2.  
  3. Install new heater core O-rings.
  4.  
  5. Install the heater pipes to the heater core; then, the 2 heater pipes-to-heater core screws and clips.
  6.  
  7. Install the heater hoses to the heater core.
  8.  
  9. Install the instrument panels No. 2 brace.
  10.  
  11. Install the instrument panel by performing the following procedure:

    Install the instrument panel and the instrument panel-to-chassis nuts/bolts.
     
    Install instrument panel electrical connectors.
     
    Install the combination meter and the 4 combination meter screws.
     
    Install the cluster finish panel, the 6 cluster finish panel assembly screws.
     
    Install the cluster finish panel.
     
    If equipped with a column shifter, install the finish panel.
     
    If equipped with a floor shifter, install the upper console panel, the rear console box and the front console box.
     
    Install the heater control assembly.
     
    Install the center cluster finish panel and the radio.
     
    Carefully, install the air bag module to the instrument panel; then, install the passenger-s side air bag module-to-instrument panel 2 bolts and 4 nuts.
     
    Install the glove compartment and the 4 glove compartment-to-instrument panel screws; then, install the glove box light connector.
     
    Install the glove compartment door and the 3 door-to-instrument panel nuts.
     
    Connect the air bag electrical connector.
     
    Inside the glove compartment, install the glove compartment door finish plate.
     
    Install the steering column assembly and the steering column-to-instrument panel nuts; then, torque the nuts to 19 ft. lbs. (25 Nm).
     
    Align the matchmarks and install the steering column shaft-to-intermediate shaft bolt.
     
    If equipped with a column shifter, install the shift control cable to the shift lever housing; then, install the shift control cable to the steering column cable bracket.
     
    Install the lower No. 2 finish panel.
     
    Install the parking brake release lever and the No. 2 undercover.
     
    Install the fuse box bolt and the No. 2 heater-to-register duct.
     
    Install the lower finish panel assembly and the instrument panel finish lower left side panel.
     
    Install the steering column covers and the combination switch.
     
    Install the hood lock release lever and the cowl side trims.
     
    Install the front pillar garnishes and the door scuff plates.
     

  12.  
  13. Install the air bag module and the steering wheel by performing the following procedure:

    Align the matchmarks and install the steering wheel to the steering column.
     
    Install the steering wheel nut and torque to 26 ft. lbs. (35 Nm).
     
    Carefully, connect the electrical connector and install the air bag module.
     
    Using a Torx socket, tighten the 2 air bag module-to-steering wheel Torx screws to 78 inch lbs. (8.8 Nm).
     
    At both sides of the steering wheel, install the screw covers.
     

  14.  
  15. Refill the cooling system.
  16.  
  17. Install the negative battery cable.
  18.  
  19. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  20.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Discharge and recover the refrigerant from the air conditioning system.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Wiper arm and blade assembly
     
    Right-side top cowl ventilator louver
     
    Wiper motor and linkage assembly
     
    Outside top cowl panel
     
    Air conditioner lines
     
    Heater hoses
     

  8.  
  9. To remove the instrument panel safety pad, remove or disconnect the following:

    Steering wheel covers
     
    Horn button
     
    Steering wheel assembly
     
    Steering column covers
     
    Turn signal switch assembly
     
    Instrument cluster finishing trim
     
    Instrument panel trim around the steering column
     
    Instrument panel center panel
     
    Radio
     
    Instrument cluster cover
     
    Gauge cluster assembly
     
    Accessory cluster assembly
     
    Instrument panel registers
     
    Speaker covers
     
    Front speakers
     
    Side cowl trim
     
    Front door scuff plates
     
    Instrument panel under cover
     
    Lower finishing panels
     
    Lower instrument panel airbag assembly
     
    Shift lever knob
     
    Shift indicator housing
     
    Seat heater switch, if equipped
     
    Center console upper panel

    Click image to see an enlarged view

    Fig. Location of the clips holding the center console-2005-06 Avalon

     



    Center console
     
    Lower center instrument panel
     
    Instrument side panels
     
    A-pillar trim
     
    Passenger airbag connector
     
    Instrument panel safety pad

    Click image to see an enlarged view

    Fig. Location of the instrument panel mounting clips and nuts-2005-06 Avalon

     

  10.  
  11. Remove or disconnect the following:

    No. 2 heater duct
     
    No. 6 heater duct
     
    Console box duct
     
    Floor carpet brackets
     
    Rear air ducts
     
    No. 1 air duct
     
    Steering intermediate shaft
     
    Steering column assembly
     
    Instrument panel reinforcement

    Click image to see an enlarged view

    Fig. Location of the clamps for the instrument panel reinforcement wiring harness-2005-06 Avalon



    Click image to see an enlarged view

    Fig. Location of the mounting points for the instrument panel reinforcement and exploded view of the ventilation system-2005-06 Avalon

     



    Blower assembly
     

  12.  
  13. Remove or disconnect the following from the blower assembly:

    Air outlet control servomotor
     
    Air mix control servomotor
     
    Heater pipe clamps
     
    Heater core
     

  14.  
  15. Installation is the reverse order of removal.
  16.  
  17. Refill the cooling system to the correct level.
  18.  
  19. Start the engine and check for leaks.
  20.  


NOTE
Removal of the heater core requires removal of the entire heater air conditioning assembly.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  5. Disconnect the negative battery cable. Wait 90 seconds before doing any further work while the airbag system de-energizes.
  6.  
  7. Discharge and recover the air conditioning system refrigerant.
  8.  
  9. Disconnect A/C suction hose (No. 1) and Liquid pipe (A)
    1. Install SST to piping clamp
    2.  
    3. Push down SST and release the clamp lock
      WARNING
      Be careful not to deform the tube, when pushing the SST


      NOTE
      Cap the open fittings immediately to prevent system contamination

    4.  

  10.  
  11. Remove or disconnect the following:

    Heater core hoses
     

  12.  
  13. Disassemble the dash components as follows
    WARNING
    Follow air bag removal procedures



    Lower steering column cover
     
    Steering wheel
     
    Instrument cluster finish panel sub-assembly
     
    Steering column cover
     
    Headlamp dimmer switch assembly
     
    Windshield wiper switch assembly
     
    Combination meter assembly
     
    Door scuff plates
     
    LH instrument panel under cover sub-assembly
     
    Cowl side trim
     
    Coin box
     
    LH upper instrument panel sub assembly
     
    LH lower instrument panel brace
     
    Air conditioning control assembly

    Click image to see an enlarged view

    Fig.  Instrument cluster finish panel clip locations-Camry



    Click image to see an enlarged view

    Fig.  Air conditioning control panel clips-Camry



    Click image to see an enlarged view

    Fig. Radio panel clips-Camry

     
    Instrument panel center cluster finish panel
     
    Glove box door
     
    RH lower instrument panel sub-assembly
     
    Shift lever knob on M/T
     
    Remove the console panel
     
    Rear console box
     
    Cup holder and ashtray
     
    Upper console panel
     
    Front console box
     
    Instrument panel finish plate
     
    LH & RH front pillar garnish
     
    Instrument panel speakers
     
    Passenger air bag connector
     
    Instrument panel safety pad cap
     
    Instrument panel safety pad sub-assembly
     

  14.  
  15. Remove or disconnect the following:

    Rear air ducts
     
    Console box duct
     
    Floor shift parking lock cable assembly
     
    Windshield wiper relay assembly
     
    Instrument panel brace assemblies
     
    Lower instrument finish panel retainer
     
    Heater to foot ducts
     
    Steering column assembly
     
    Instrument panel reinforcements
     
    Heater blower assembly
     
    Lower defroster nozzles
     
    Air conditioning radiator assembly
     
    Mode damper servo sub-assembly
     
    Airmix damper servo sub-assembly
     
    Heater radiator (core) sub-assembly

    Click image to see an enlarged view

    Fig. Instrument panel safety pad fastener locations-Camry



    Click image to see an enlarged view

    Fig.  Air conditioning radiator assembly-Camry

     

  16.  

To install:

Install or connect the following:

  1. Heater core unit sub assembly

    Heater core into A/C assembly
     
    Screw and clamp
     
    Air conditioning radiator assembly
     
    Lower defroster nozzles
     
    Heater blower assembly
     
    Instrument panel reinforcements
     
    Steering column assembly
     
    Heater to foot ducts
     
    Lower instrument finish panel retainer
     
    Instrument panel brace assemblies
     
    Windshield wiper relay assembly and
     
    Floor shift parking lock cable assembly
     
    Console box duct
     
    Rear air ducts
     

  2.  
  3. Reassemble the dash components in the reverse of removal.
  4.  
  5. Install or connect the following:
    NOTE
    Lubricate O-rings with compressor oil



    Heater core hoses
     
    A/C suction and pressure hoses, attach with bolt and plate
     



    Negative battery cable
     

  6.  
  7. Refill the cooling system to the correct level.
  8.  
  9. Evacuate and recharge A/C system
  10.  
  11. Start the engine and check for leaks.
  12.  

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  5. Disconnect the heater hoses from the heater core.
  6.  
  7. At the driver-s side, remove the lower instrument panel.
  8.  
  9. Remove the left hand instrument lower panel.
  10.  
  11. At the heater/air conditioning housing, disengage the 3 heater protector-to-heater/air conditioning housing clips and remove the heater protector.
  12.  
  13. Remove the 3 heater core pipe clamp screws and the clamps.
  14.  
  15. Remove the 2 heater core pipe clamp screws and the clamps; then, disconnect the pipes from the heater core.
  16.  
  17. Remove the heater core.

    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel, heater/air conditioning housing and related components-Solara



    Click image to see an enlarged view

    Fig. Exploded view of the heater/air conditioning housing, heater core, evaporator core and related components-Solara



    Click image to see an enlarged view

    Fig. View of the heater core-Solara

  18.  

To install:

  1. Install the heater core.
  2.  
  3. Connect the pipes to the heater core and install the heater core pipe clamp and the 2 clamp screws.
  4.  
  5. Install the heater core pipe clamps and the 3 clamp screws.
  6.  
  7. At the heater/air conditioning housing, install the heater protector and engage the 3 heater protector-to-heater/air conditioning housing clips.
  8.  
  9. Install the left hand instrument lower panel.
  10.  
  11. At the driver-s side, install the lower instrument panel.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Connect the heater hoses to the heater core.
  16.  
  17. Refill the cooling system to the correct level.
  18.  

 
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