| Last Modified: 01-30-2024 | 6.11:8.1.0 | Doc ID: RM100000001QI6T |
| Model Year Start: 2021 | Model: RAV4 | Prod Date Range: [08/2020 - ] |
| Title: HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT (for A25A-FKS): REASSEMBLY; 2021 - 2024 MY RAV4 [08/2020 - ] | ||
REASSEMBLY
PROCEDURE
1. INSTALL HEATER COVER (for TMC Made)
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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
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4. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
(a) Install the new No. 1 cooler evaporator sub-assembly with No. 1 cooler thermistor to the upper heater case.
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*A |
for Type A |
*B |
for Type B |
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.
(b) Attach the guide.
(c) While inserting the No. 1 cooler thermistor into the guide, attach the guide and claw as shown in the illustration.
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*a |
No. 1 Cooler Thermistor Lead Wire |
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- |
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Secure the lead wire between the guide |
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(d) 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 12 or equivalent
(c) Install the 2 O-rings to the No. 1 cooler evaporator sub-assembly.
NOTICE:
Keep the O-rings and O-ring fitting surfaces free of foreign matter.
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(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) |
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6. INSTALL COOLING UNIT PARTS
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(a) Install the cooling unit parts. |
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7. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY
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8. INSTALL HEATER CLAMP
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9. INSTALL HEATER PIPE GROMMET
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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.
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*a |
Link A |
*b |
Link B |
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*c |
Link C |
*d |
Groove |
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(b) Attach the guide. |
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(c) Install the No. 3 air conditioning radiator damper servo sub-assembly with the 2 screws.
11. INSTALL NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (w/ Rear Register Duct)
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12. INSTALL NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY
(a) for Automatic Air Conditioning System:
(1) 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.
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*a |
Gear Alignment Part |
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(b) for Manual Air Conditioning System:
(1) Align the fitting part of the heater case with the fitting part of the No. 1 air conditioning radiator damper servo sub-assembly as shown in the illustration.
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(c) Attach the guide. |
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(d) Install the No. 1 air conditioning radiator damper servo sub-assembly with the 3 screws.
13. INSTALL AIR CONDITIONING HARNESS ASSEMBLY
(a) Attach the clamp and guide.
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*A |
w/ Driver Seat Centralized Control |
*B |
w/o Driver Seat Centralized Control |
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*C |
w/ Rear Register Duct |
*D |
w/o Rear Register Duct |
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*a |
Clamp |
*b |
Guide |
(b) Connect each connector to install the air conditioning harness assembly.
14. INSTALL NO. 2 COOLER UNIT DRAIN HOSE (Available as Supply Part)
HINT:
Perform this procedure only when the No. 2 cooler unit drain hose is available as a supply part.
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(a) Install the No. 2 cooler unit drain hose. |
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15. INSTALL DRAIN COOLER HOSE
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16. INSTALL COOLER THERMISTOR (ROOM TEMPERATURE SENSOR) (for Automatic Air Conditioning System)
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17. INSTALL ASPIRATOR (for TMC Made Automatic Air Conditioning System)
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18. INSTALL ASPIRATOR PIPE (for TMMC Made Automatic Air Conditioning System)
HINT:
Use the same procedure described as for the aspirator (for TMC Made Automatic Air Conditioning System).
19. INSTALL GROMMET (for TMC Made Manual Air Conditioning System)
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(a) Attach the claw to install the grommet. NOTICE: Firmly push it down into the heater case until a "click" sound is heard. |
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20. INSTALL COVER PLATE (for TMMC Made Manual Air Conditioning System)
HINT:
Use the same procedure described as for the grommet (for TMC Made Manual Air Conditioning System).
21. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY (for TMC Made)
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22. 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).
23. INSTALL BLOWER ASSEMBLY
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