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    1990 Buick Skylark 2.5L TBI OHV 4cyl

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    Toyota Avalon, Camry, Camry Solara 2001-06

    Removal & Installation

    Print

    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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