HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT (for A25A-FXS): REASSEMBLY; 2019 - 2020 MY RAV4 HV [02/2019

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM100000001H3Y5
Model Year Start: 2019	Model: RAV4 HV	Prod Date Range: [02/2019 - 08/2020]
Title: HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT (for A25A-FXS): REASSEMBLY; 2019 - 2020 MY RAV4 HV [02/2019 - 08/2020]

REASSEMBLY

PROCEDURE

1. INSTALL HEATER COVER (for TMC Made)

Perform this procedure only when removal/installation of the heater cover is necessary.

NOTICE:

After removing the heater cover, the heater cover itself can be reused, but the air conditioning radiator assembly cannot be reused. After the heater cover is installed, the support (triangular rib) on the air conditioning radiator assembly is crushed. Therefore, if the air conditioning radiator assembly is reused, abnormal noise may occur due to looseness.

(a) Install the heater cover to a new lower heater case as shown in the illustration.

Install in this Direction

(b) Install the screw.

2. INSTALL NO. 2 HEATER COVER (for TMMC Made)

Perform this procedure only when removal/installation of the No. 2 heater cover is necessary.

NOTICE:

After removing the No. 2 heater cover, the No. 2 heater cover itself can be reused, but the air conditioning radiator assembly cannot be reused. After the No. 2 heater cover is installed, the support (triangular rib) on the air conditioning radiator assembly is crushed. Therefore, if the air conditioning radiator assembly is reused, abnormal noise may occur due to looseness.

HINT:

Use the same procedure described as for the heater cover (for TMC Made).

3. INSTALL NO. 1 COOLER THERMISTOR

Click here

4. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY

(a) for HFC-134a(R134a):

(1) Install the No. 1 cooler evaporator sub-assembly with No. 1 cooler thermistor to the upper heater case.

for Type A

for Type B

(b) for HFO-1234yf(R1234yf):

(1) Install the new No. 1 cooler evaporator sub-assembly with No. 1 cooler thermistor to the upper heater case.

NOTICE:

When the No. 1 cooler evaporator sub-assembly is removed, make sure to install a new one. The No. 1 cooler evaporator sub-assembly cannot be reused.

(d) While inserting the No. 1 cooler thermistor into the guide, attach the guide and claw as shown in the illustration.

*a	No. 1 Cooler Thermistor Lead Wire	-	-
	Secure the lead wire between the guide	-	-

(e) Install the upper heater case with No. 1 cooler evaporator sub-assembly to the lower heater case with the 2 screws.

5. INSTALL COOLER EXPANSION VALVE

(a) Remove the vinyl tape from the No. 1 cooler evaporator sub-assembly and cooler expansion valve.

(b) Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces of the No. 1 cooler evaporator sub-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.

NOTICE:

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

(d) Using a 4 mm hexagon socket wrench, install the cooler expansion valve with the 2 hexagon bolts.

Torque:

3.5 N·m {36 kgf·cm, 31 in·lbf}

NOTICE:

Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)

*A	for Type A
*B	for Type B

6. INSTALL COOLING UNIT PARTS

(a) Install the cooling unit parts.

*A	for Type A
*B	for Type B

7. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY

(a) Install the heater radiator unit sub-assembly as shown in the illustration.

Install in this Direction

8. INSTALL HEATER CLAMP

(a) Attach the claw to install the heater clamp.

9. INSTALL HEATER PIPE GROMMET

(a) Install the heater pipe grommet as shown in the illustration.

NOTICE:

Install the heater pipe grommet with the arrow facing up.

10. INSTALL NO. 3 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (w/ Driver Seat Centralized Control)

(a) Attach the No. 3 air conditioning radiator damper servo sub-assembly to the 3 links of the heater case as shown in the illustration.

HINT:

Attach link B to the groove shown in the illustration.

*a	Link A	*b	Link B
*c	Link C	*d	Groove

(b) Attach the guide.

11. INSTALL NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY

(a) Align the gear alignment part of the heater case with the gear alignment part of the No. 2 air conditioning radiator damper servo sub-assembly as shown in the illustration.

*a	Gear Alignment Part

(b) Attach the guide.

12. INSTALL NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY

(a) Align the fitting part and gear alignment part of the heater case with the fitting part and gear alignment part of the No. 1 air conditioning radiator damper servo sub-assembly as shown in the illustration.

Gear Alignment Part

(b) Attach the guide.

13. INSTALL AIR CONDITIONING HARNESS ASSEMBLY

(a) Attach the clamp and guide.

*A	w/ Driver Seat Centralized Control	-	-
*a	Clamp	*b	Guide

(b) Connect each connector to install the air conditioning harness assembly.

14. INSTALL DRAIN COOLER HOSE

(a) Align the hose notch with the rib as shown in the illustration and install the drain cooler hose.

NOTICE:

Do not place the rib on top of the drain cooler hose. Otherwise, water may leak into the interior.

*a	Hose Notch
*b	Rib

15. INSTALL COOLER THERMISTOR (ROOM TEMPERATURE SENSOR)

(a) Install the cooler thermistor (room temperature sensor).

NOTICE:

Securely insert it up to the base.

16. INSTALL ASPIRATOR (for TMC Made)

(a) Attach the claw to install the aspirator.

NOTICE:

Firmly push it down into the heater case until a "click" sound is heard.

(b) Attach the clamp.

17. INSTALL ASPIRATOR PIPE (for TMMC Made)

HINT:

Use the same procedure described as for the aspirator (for TMC Made).

18. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY (for TMC Made)

(a) Attach the claw to install the No. 2 air duct sub-assembly.

Firmly push it down into the heater case until a "click" sound is heard.

NOTICE:

If the claws are not securely pushed in, a gap may form between the heater case and duct, and air leaking from the gap may cause abnormal noise and reduced performance. Also, the audio system may be exposed to cool air, causing it to malfunction.

19. INSTALL NO. 4 AIR DUCT SUB-ASSEMBLY (for TMMC Made)

HINT:

Use the same procedure described as for the No. 2 air duct sub-assembly (for TMC Made).

20. INSTALL BLOWER ASSEMBLY

Click here