| Last Modified: 01-30-2024 | 6.11:8.1.0 | Doc ID: RM100000001QI6Z |
| Model Year Start: 2021 | Model: RAV4 | Prod Date Range: [08/2020 - 10/2022] |
| Title: HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT (for A25A-FKS): INSTALLATION; 2021 - 2022 MY RAV4 [08/2020 - 10/2022] | ||
INSTALLATION
CAUTION / NOTICE / HINT
HINT:
A bolt without a torque specification is shown in the standard bolt chart.
Click here
![2019 - 2024 MY RAV4 RAV4 HV [11/2018 - ]; SPECIFICATIONS: STANDARD BOLT: SPECIFIED TORQUE FOR STANDARD BOLTS](/t3Portal/stylegraphics/info.gif)
PROCEDURE
1. INSTALL COOLER UNIT DRAIN HOSE GROMMET
Click here
2. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY (for TMC Made)
Click here
3. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY (for TMMC Made)
HINT:
- Perform this procedure only when removal/installation of the No. 3 air duct sub-assembly is necessary.
- Use the same procedure described as for the No. 1 air duct sub-assembly (for TMC Made).
4. INSTALL AIR CONDITIONING UNIT ASSEMBLY
Click here
5. INSTALL ID CODE BOX (IMMOBILIZER CODE ECU) (w/ ID Code Box)
Click here
6. INSTALL TRANSPONDER KEY ECU (IMMOBILIZER CODE ECU) (w/ Transponder ECU)
Click here
7. CONNECT INSTRUMENT PANEL WIRE
(a) Attach the clamp.
|
*A |
w/ ECU |
- |
- |
(b) Connect the connector.
8. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY
Click here
9. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT ASSEMBLY
Click here
10. INSTALL HEATER GROMMET
Click here
11. CONNECT DRAIN COOLER HOSE
Click here
12. TEMPORARILY INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY
Click here
13. TEMPORARILY INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY
Click here
14. TIGHTEN INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT ASSEMBLY
Click here
15. CONNECT INSTRUMENT PANEL WIRE
Click here
16. INSTALL ECU INTEGRATION BOX RH
Click here
17. CONNECT INSTRUMENT PANEL WIRE
(a) Connect the lever connector.
Click here
|
*A |
for Type A |
*B |
for Type B |
|
*C |
for Automatic Air Conditioning System |
- |
- |
|
*a |
Clamp |
*b |
Guide |
|
Bolt |
|
Nut |
|
Connector |
|
Lever Connector |
(b) Attach the clamp.
(c) Connect the connector.
(d) Attach the guide.
(e) Connect the ground wire with the bolt.
Torque:
8.5 N·m {87 kgf·cm, 75 in·lbf}
(f) Install the nut.
Torque:
8.0 N·m {82 kgf·cm, 71 in·lbf}
(g) Attach the clamp.
|
*a |
Clamp |
*b |
Guide |
(h) Attach the guide.
(i) Connect the 3 ground wires with the 3 bolts.
Torque:
8.5 N·m {87 kgf·cm, 75 in·lbf}
|
(j) Connect the 2 connectors. |
|
(k) Attach the guide and clamp.
18. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU
Click here
19. INSTALL NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY (for TMC Made)
Click here
20. INSTALL CENTER INSTRUMENT PANEL BRACKET SUB-ASSEMBLY (for TMMC Made)
HINT:
Use the same procedure described as for the No. 3 instrument panel to cowl brace sub-assembly (for TMC Made).
21. INSTALL NO. 2 HEATER TO REGISTER DUCT SUB-ASSEMBLY
Click here
22. INSTALL NO. 1 CONSOLE BOX DUCT (w/ Rear Register Duct)
Click here
23. INSTALL REAR NO. 3 AIR DUCT (for TMC Made)
Click here
24. INSTALL REAR NO. 2 AIR DUCT (for TMMC Made)
HINT:
Use the same procedure described as for the rear No. 3 air duct (for TMC Made).
25. INSTALL REAR NO. 4 AIR DUCT (for TMC Made)
Click here
26. INSTALL REAR NO. 4 AIR DUCT (for TMMC Made)
HINT:
Use the same procedure described as for the rear No. 4 air duct (for TMC Made).
27. INSTALL REAR NO. 1 AIR DUCT
HINT:
Use the same procedure described as for the rear No. 3 air duct (for TMC Made).
28. INSTALL REAR NO. 2 AIR DUCT (for TMC Made)
HINT:
Use the same procedure described as for the rear No. 4 air duct (for TMC Made).
29. INSTALL REAR NO. 3 AIR DUCT (for TMMC Made)
HINT:
Use the same procedure described as for the rear No. 4 air duct (for TMC Made).
30. INSTALL NO. 3 DASH PANEL INSULATOR PAD
Click here
31. INSTALL FRONT FLOOR FRONT CARPET ASSEMBLY
Click here
32. INSTALL FRONT FLOOR CAUTION PLATE COVER (w/ Cover)
Click here
33. INSTALL ACCELERATOR PEDAL ASSEMBLY
Click here
34. INSTALL ACCELERATOR PEDAL PAD
Click here
35. INSTALL LOWER CENTER PILLAR GARNISH LH
(a) Install the lower center pillar garnish LH.
Click here
(b) Return the front door opening trim weatherstrip LH to its original position.
Click here
(c) Return the rear door opening trim weatherstrip LH to its original position.
Click here
36. INSTALL FRONT SEAT OUTER BELT ASSEMBLY LH
Click here
37. INSTALL REAR DOOR SCUFF PLATE LH
Click here
38. INSTALL LOWER CENTER PILLAR GARNISH RH
HINT:
Use the same procedure described as for the lower center pillar garnish LH.
39. INSTALL FRONT SEAT OUTER BELT ASSEMBLY RH
HINT:
Use the same procedure described as for the front seat outer belt assembly LH.
40. INSTALL REAR DOOR SCUFF PLATE RH
HINT:
Use the same procedure described as for the rear door scuff plate LH.
41. INSTALL OUTER LAP BELT ANCHOR COVER
Click here
42. INSTALL NAVIGATION ECU WITH BRACKET (w/ Navigation System)
(a) w/o DCM:
Click here
(b) w/ DCM:
Click here
43. INSTALL DCM (TELEPHONE TRANSCEIVER ASSEMBLY) WITH BRACKET (w/ DCM)
(a) w/ Navigation System:
Click here
(b) w/o Navigation System:
Click here
44. INSTALL STEERING COLUMN ASSEMBLY
Click here
45. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY
Click here
46. INSTALL FRONT SEAT ASSEMBLY LH
(a) for Manual Seat:
Click here
(b) for Power Seat:
Click here
47. INSTALL FRONT SEAT ASSEMBLY RH
HINT:
Use the same procedure as for the LH side.
48. CONNECT INLET HEATER WATER HOSE
(a) Connect the inlet heater water hose as shown in the illustration.
NOTICE:
- Do not apply excessive force to the inlet heater water hose.
- Make sure the inlet heater water hose is securely inserted to the stopper. However, If the end of the inlet heater water hose is cut diagonally, it is acceptable for the entire circumference of the tip to not contact the stopper.
- Connect the inlet heater water hose so that its marking faces the top of the vehicle.
|
*1 |
Hose Clip |
*2 |
Inlet Heater Water Hose |
|
*a |
View A |
*b |
Stopper |
|
*c |
Hose Clip Installation Angle (270°) |
*d |
Hose Clip Installation Range (2 to 7 mm (0.0787 to 0.276 in.)) |
(b) Make sure to install the hose clip within the range shown in the illustration.
49. CONNECT OUTLET HEATER WATER HOSE
(a) Connect the outlet heater water hose as shown in the illustration.
NOTICE:
- Do not apply excessive force to the outlet heater water hose.
- Make sure the outlet heater water hose is securely inserted to the stopper. However, If the end of the outlet heater water hose is cut diagonally, it is acceptable for the entire circumference of the tip to not contact the stopper.
- Connect the outlet heater water hose so that its marking faces the top of the vehicle.
|
*1 |
Hose Clip |
*2 |
Outlet Heater Water Hose |
|
*a |
View A |
*b |
Stopper |
|
*c |
Hose Clip Installation Angle (270°) |
*d |
Hose Clip Installation Range (2 to 7 mm (0.0787 to 0.276 in.)) |
(b) Make sure to install the hose clip within the range shown in the illustration.
NOTICE:
Make sure that the hose clamps do not contact each other.
50. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (w/o Sub-cool Accelerator)
(a) Remove the vinyl tape wrapped around the connection of the air conditioning tube and accessory assembly and the air conditioning tube and accessory assembly.
(b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioning tube and accessory assembly.
Compressor Oil:
ND-OIL 12 or equivalent
(c) Install the O-ring to the air conditioning tube and accessory assembly.
NOTICE:
Keep the O-ring and O-ring fitting surface free from foreign matter.
(d) Connect the air conditioning tube and accessory assembly.
NOTICE:
- Do not apply excessive force to the air conditioning tube and accessory assembly.
- Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)
51. CONNECT SUCTION PIPE SUB-ASSEMBLY (for TMC Made without Sub-cool Accelerator)
(a) Remove the vinyl tape wrapped around the connection of the suction pipe sub-assembly and suction pipe sub-assembly.
(b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction pipe sub-assembly.
Compressor Oil:
ND-OIL 12 or equivalent
(c) Install the O-ring to the suction pipe sub-assembly.
NOTICE:
Keep the O-ring and O-ring fitting surface free of foreign matter.
(d) Connect the suction pipe sub-assembly.
NOTICE:
- Do not apply excessive force to the suction pipe sub-assembly.
- Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)
(e) Rotate the 1-point tightening plate as shown in the illustration.
|
Rotate in this Direction |
|
(f) Insert the tube joint into the fitting hole securely and install the bolt. Torque: 9.8 N·m {100 kgf·cm, 87 in·lbf} |
|
52. CONNECT SUCTION TUBE SUB-ASSEMBLY B (for TMMC Made without Sub-cool Accelerator)
HINT:
Use the same procedure described as for the suction pipe sub-assembly (for TMC Made without Sub-cool Accelerator).
53. CONNECT NO. 2 AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (for TMC Made with Sub-cool Accelerator)
(a) Remove the vinyl tape wrapped around the connection of the No. 2 air conditioning tube and accessory assembly and the No. 2 air conditioning tube and accessory assembly.
(b) Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces of the No. 2 air conditioning tube and accessory assembly.
Compressor Oil:
ND-OIL 12 or equivalent
(c) Install the 2 O-rings to the No. 2 air conditioning tube and accessory assembly.
NOTICE:
Keep the O-rings and O-ring fitting surfaces free of foreign matter.
(d) Connect the No. 2 air conditioning tube and accessory assembly.
NOTICE:
- Do not apply excessive force to the No. 2 air conditioning tube and accessory assembly.
- Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)
(e) Rotate the 1-point tightening plate as shown in the illustration.
|
|
Rotate in this Direction |
|
(f) Insert the tube joint into the fitting hole securely and install the bolt. Torque: 9.8 N·m {100 kgf·cm, 87 in·lbf} |
|
54. CONNECT SUCTION TUBE SUB-ASSEMBLY B (for TMMC Made with Sub-cool Accelerator)
HINT:
Use the same procedure described as for the No. 2 air conditioning tube and accessory assembly (for TMC Made with Sub-cool Accelerator).
55. INSTALL HOLE PLUG
Click here
56. INSTALL COWL VENTILATOR PANEL SUB-ASSEMBLY
(a) Install the cowl ventilator panel sub-assembly with the 4 bolts and 4 nuts.
Torque:
Bolt :
5.5 N·m {56 kgf·cm, 49 in·lbf}
Nut :
21 N·m {214 kgf·cm, 15 ft·lbf}
|
|
Bolt |
|
Nut |
(b) Attach the clamp.
(c) w/ Windshield Deicer System:
|
(1) Attach the clamp. |
|
57. INSTALL COWL VENTILATOR SPLASH SHIELD (for TMC Made)
Click here
58. INSTALL COWL VENTILATOR SPLASH SHIELD (for TMMC Made)
HINT:
Use the same procedure described as for the cowl ventilator splash shield (for TMC Made).
59. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
Click here
60. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT
Click here
61. ADD ENGINE COOLANT
Click here
62. INSPECT FOR COOLANT LEAK
Click here
63. WARM UP ENGINE
Click here
64. INSPECT FOR REFRIGERANT LEAK
Click here
|
|