Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000001FAOG
Model Year Start: 2019 Model: RAV4 HV Prod Date Range: [11/2018 - 02/2019]
Title: HEATING / AIR CONDITIONING: COMPRESSOR (for A25A-FXS): INSTALLATION; 2019 MY RAV4 HV [11/2018 - 02/2019]

INSTALLATION

PROCEDURE

1. ADJUST COMPRESSOR OIL

(a) When replacing the compressor with motor assembly with a new one, gradually discharge the inert gas from the service valve, and drain the following amount of oil from the new compressor with motor assembly before installation.

Standard:

(Oil capacity inside the new compressor with motor assembly: 120 to 135 cc (4.06 to 4.56 fl. oz)) - (Remaining oil amount in the removed compressor with motor assembly) = (Oil amount to be removed from the new compressor with motor assembly)

NOTICE:

  • If a new compressor with motor assembly is installed without removing some oil, there will be too much oil in the system due to the oil remaining in the pipes of the vehicle. Excessive oil in the system prevents heat exchange in the refrigeration cycle and causes ineffective cooling.
  • If the amount of oil remaining in the old compressor with motor assembly is too small, check the air conditioning system for oil leaks.
  • Be sure to use ND-OIL 11 or equivalent compressor oil. If any compressor oil other than ND-OIL 11 is used, compressor with motor assembly insulation performance may decrease, resulting in leakage of electric power.

2. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY

(a) Remove the insulating tape from the connector (B).

Connector (B)

Slide

Green-colored Lock

(b) Connect the connector (B) and slide the green-colored lock as shown in the illustration to securely lock it.

CAUTION:

Make sure to wear insulated gloves.

NOTICE:

Make sure that the connector is connected securely.

(c) Using an E8 "TORX" socket wrench, temporarily install the compressor with motor assembly with the 2 stud bolts and bolt.

Bolt

Stud Bolt

Torque:

Stud Bolt :

5.0 N·m {51 kgf·cm, 44 in·lbf}

(d) Install the compressor with motor assembly with the bolt and 2 nuts.

Bolt

Nut

Torque:

24.5 N·m {250 kgf·cm, 18 ft·lbf}

HINT:

Tighten the bolts and nuts in the order shown in the illustration, or temporarily install 3 of them, and then tighten them in the order 1, 2 and 3.

(e) Connect the connector (A).

Connector (A)

3. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

(a) Remove the vinyl tape wrapped around the connection of the No. 1 cooler refrigerant discharge hose and No. 1 cooler refrigerant discharge hose.

(b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor with motor assembly.

Compressor Oil:

ND-OIL 11 or equivalent

NOTICE:

Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in leakage of electric power.

(c) Install the O-ring to the No. 1 cooler refrigerant discharge hose.

NOTICE:

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

(d) Connect the No. 1 cooler refrigerant discharge hose with the bolt.

Torque:

9.8 N·m {100 kgf·cm, 87 in·lbf}

NOTICE:

  • Do not apply excessive force to the No. 1 cooler refrigerant discharge hose.
  • Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)

4. CONNECT SUCTION HOSE SUB-ASSEMBLY

(a) Remove the vinyl tape wrapped around the connection of the suction hose sub-assembly and suction hose sub-assembly.

(b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor with motor assembly.

Compressor Oil:

ND-OIL 11 or equivalent

NOTICE:

Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in leakage of electric power.

(c) Install the O-ring to the suction hose sub-assembly.

NOTICE:

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

(d) Connect the suction hose sub-assembly.

Torque:

9.8 N·m {100 kgf·cm, 87 in·lbf}

NOTICE:

  • Do not apply excessive force to the suction hose sub-assembly.
  • Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)

5. INSTALL FRONT FENDER LINER RH

Click here 2019 - 2020 MY RAV4 RAV4 HV [11/2018 - 08/2020]; WIPER / WASHER: WASHER MOTOR: INSTALLATION+

6. INSTALL FRONT FENDER APRON SEAL RH

Click here 2019 MY RAV4 HV [11/2018 - 02/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION+

7. INSTALL FRONT FENDER MUDGUARD RH (w/ Mudguard)

HINT:

Use the same procedure described as for the LH side.

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; EXTERIOR PANELS / TRIM: MUDGUARD: INSTALLATION+

8. INSTALL NO. 1 ENGINE UNDER COVER

Click here 2019 MY RAV4 HV [11/2018 - 02/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION+

9. INSTALL FRONT FENDER FRONT SPLASH SHIELD LH

Click here 2019 MY RAV4 HV [11/2018 - 02/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION+

10. INSTALL FRONT FENDER FRONT SPLASH SHIELD RH

Click here 2019 MY RAV4 HV [11/2018 - 02/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION+

11. INSTALL FRONT FENDER MOULDING SUB-ASSEMBLY RH

HINT:

Use the same procedure described as for the LH side.

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; EXTERIOR PANELS / TRIM: WHEEL OPENING MOULDING (for Front): INSTALLATION+

12. INSTALL FRONT WHEEL RH

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; MAINTENANCE: TIRE AND WHEEL: INSTALLATION

13. INSTALL SERVICE PLUG GRIP

Click here 2019 - 2024 MY RAV4 HV [11/2018 -        ]; HYBRID / BATTERY CONTROL: SERVICE PLUG GRIP: INSTALLATION

14. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

Click here 2019 - 2020 MY RAV4 RAV4 HV [11/2018 - 08/2020]; HEATING / AIR CONDITIONING: REFRIGERANT (for HFC-134a(R134a)): REPLACEMENT+

15. WARM UP COMPRESSOR

Click here 2019 - 2020 MY RAV4 RAV4 HV [11/2018 - 08/2020]; HEATING / AIR CONDITIONING: REFRIGERANT (for HFC-134a(R134a)): REPLACEMENT+

16. INSPECT FOR REFRIGERANT LEAK

Click here 2019 - 2020 MY RAV4 RAV4 HV [11/2018 - 08/2020]; HEATING / AIR CONDITIONING: REFRIGERANT (for HFC-134a(R134a)): REPLACEMENT+