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Home >> Toyota >> 2020 >> RAV4 LE, AWD >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> Heating / Air Conditioning System - Service Information (2 Of 5) >> AIR CONDITIONING UNIT (for A25A-FXS) >> Removal [10/2019 - 08/2020] >> Procedure

Removal [10/2019 - 08/2020]: Procedure

  1. PRECAUTION 
    NOTE:

    Make sure to select face mode before disconnecting the cable from the negative (-) auxiliary battery terminal.

  2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  3. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 
    1. for HFC-134a(R134a):

      Refer to PROCEDURE - Step 1

    2. for HFO-1234yf(R1234yf):

      Refer to PROCEDURE - Step 1

  4. DRAIN ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 1

  5. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [11/2018 - ]

  6. REMOVE COWL VENTILATOR SPLASH SHIELD (for TMC Made) 

    HINT: 

    Remove using the same procedure that is performed when replacement of the cowl ventilator splash shield is necessary.

    Refer to PROCEDURE - Step 9

  7. REMOVE COWL VENTILATOR SPLASH SHIELD (for TMMC Made) 

    HINT: 

    Use the same procedure described as for the cowl ventilator splash shield (for TMC Made).

  8. REMOVE COWL VENTILATOR PANEL SUB-ASSEMBLY 
    1. w/ Windshield Deicer System:
      1. Detach the clamp.
        GTY930008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the clamp.
      GTY871117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt Nut
    3. Remove the 4 bolts, 4 nuts and cowl ventilator panel sub-assembly.
  9. REMOVE HOLE PLUG 
    1. Remove the 2 hole plugs.
      GTY855519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. DISCONNECT SUCTION PIPE SUB-ASSEMBLY (for TMC Made) 
    1. Remove the bolt.
      GTY855522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Rotate the 1-point tightening plate as shown in the illustration.
      GTY884926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Rotate in this Direction
    3. Disconnect the suction pipe sub-assembly.
      GTY923485Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not apply excessive force to the suction pipe sub-assembly.

    4. Remove the O-ring from the suction pipe sub-assembly.
      NOTE:

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  11. DISCONNECT SUCTION TUBE SUB-ASSEMBLY B (for TMMC Made) 

    HINT: 

    Use the same procedure described as for the suction pipe sub-assembly (for TMC Made).

  12. DISCONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY 
    1. Disconnect the air conditioning tube and accessory assembly.
      GTY923484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not apply excessive force to the air conditioning tube and accessory assembly.

    2. Remove the O-ring from the air conditioning tube and accessory assembly.
      NOTE:

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  13. DISCONNECT OUTLET HEATER WATER HOSE 
    1. Using pliers, grip the claws of the clip and slide the clip to disconnect the outlet heater water hose.
      GTY923483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not apply excessive force to the outlet heater water hose.
      • Prepare a drain pan or cloth in case the coolant leaks.
  14. DISCONNECT INLET HEATER WATER HOSE 
    1. Using pliers, grip the claws of the clip and slide the clip to disconnect the inlet heater water hose.
      NOTE:
      • Do not apply excessive force to the inlet heater water hose.
      • Prepare a drain pan or cloth in case the coolant leaks.
      GTY944999Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE HEATER GROMMET 
    1. Remove the heater grommet.
      GTY923488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE FRONT SEAT ASSEMBLY LH 
    1. for Manual Seat:

      Refer to REMOVAL [10/2019 - 08/2020]

    2. for Power Seat:

      Refer to REMOVAL [10/2019 - 08/2020]

  17. REMOVE FRONT SEAT ASSEMBLY RH 

    HINT: 

    Use the same procedure described for the LH side.

  18. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY 

    Refer to REMOVAL [10/2019 - 08/2020]

  19. REMOVE STEERING COLUMN ASSEMBLY 

    Refer to REMOVAL [10/2019 - 08/2020]

  20. REMOVE NAVIGATION ECU WITH BRACKET (w/ Navigation System) 

    Refer to PROCEDURE - Step 5

  21. REMOVE DCM (TELEPHONE TRANSCEIVER ASSEMBLY) WITH BRACKET (w/ DCM) 
    1. w/ Navigation System:

      Refer to PROCEDURE - Step 4

    2. w/o Navigation System:

      Refer to PROCEDURE - Step 5

  22. REMOVE OUTER LAP BELT ANCHOR COVER 

    Refer to PROCEDURE - Step 32

  23. REMOVE REAR DOOR SCUFF PLATE LH 

    Refer to PROCEDURE - Step 8

  24. REMOVE FRONT SEAT OUTER BELT ASSEMBLY LH 

    Refer to PROCEDURE - Step 33

  25. REMOVE LOWER CENTER PILLAR GARNISH LH 
    1. Remove the rear side of the front door opening trim weatherstrip LH so that the lower center pillar garnish LH can be removed.

      Refer to PROCEDURE - Step 3

    2. Remove the front side of the rear door opening trim weatherstrip LH so that the lower center pillar garnish LH can be removed.

      Refer to PROCEDURE - Step 2

    3. Remove the lower center pillar garnish LH.

      Refer to PROCEDURE - Step 35

  26. REMOVE REAR DOOR SCUFF PLATE RH 

    HINT: 

    Use the same procedure described as for the rear door scuff plate LH.

  27. REMOVE FRONT SEAT OUTER BELT ASSEMBLY RH 

    HINT: 

    Use the same procedure described as for the front seat outer belt assembly LH.

  28. REMOVE LOWER CENTER PILLAR GARNISH RH 

    HINT: 

    Use the same procedure described as for the lower center pillar garnish LH.

  29. REMOVE ACCELERATOR PEDAL PAD 

    Refer to PROCEDURE - Step 5

  30. REMOVE ACCELERATOR PEDAL ASSEMBLY 

    Refer to PROCEDURE - Step 6

  31. REMOVE FRONT FLOOR CAUTION PLATE COVER (w/ Cover) 
    1. Place your fingers at the positions shown in the illustration, detach the claw and guide and open the front floor caution plate cover.
      GTY840820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Place Finger Here
    2. Detach the clip and remove the front floor caution plate cover.
      GTY923492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE FRONT FLOOR FRONT CARPET ASSEMBLY 
    1. Remove the clip.
      GTY840837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fold Back Fastener
    2. Detach the guide.
    3. Detach each fastener and fold back the front floor front carpet assembly as shown in the illustration.
    4. Remove the clip.
      GTY845849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fold Back - -
    5. Detach the guide and fold back the front floor front carpet assembly as shown in the illustration.
  33. REMOVE NO. 3 DASH PANEL INSULATOR PAD 
    1. Detach the guide and remove the No. 3 dash panel insulator pad.
      GTY923499Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE REAR NO. 4 AIR DUCT (for TMC Made) 
    1. Remove the clip.
      GTY923497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the claw and remove the rear No. 4 air duct.
  35. REMOVE 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).

  36. REMOVE REAR NO. 3 AIR DUCT (for TMC Made) 
    1. Detach the claw and remove the rear No. 3 air duct.
      GTY901088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE 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).

  38. REMOVE 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).

  39. REMOVE 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).

  40. REMOVE REAR NO. 1 AIR DUCT 

    HINT: 

    Use the same procedure described as for the rear No. 3 air duct (for TMC Made).

  41. REMOVE NO. 1 CONSOLE BOX DUCT 
    1. Remove the clip and No. 1 console box duct.
      GTY901085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE NO. 2 HEATER TO REGISTER DUCT SUB-ASSEMBLY 
    1. Remove the clip and No. 2 heater to register duct sub-assembly.
      GTY923507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY (for TMC Made) 

    Refer to PROCEDURE - Step 7

  44. REMOVE 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).

  45. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU 

    Refer to PROCEDURE - Step 9

  46. DISCONNECT INSTRUMENT PANEL WIRE 
    1. Disconnect the 2 connectors.
      GTY944772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Clamp
      *b Guide
    2. Detach the clamp and guide.
    3. Remove the 3 bolts.
      GTY916710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Clamp *b Guide
    4. Detach the guide and disconnect the 3 ground wires.
    5. Detach the clamp.
    6. Remove the nut.
      GTY857992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Type A *B for Type B
      *a Clamp *b Guide
      Bolt Nut
      Connector Lever Connector
    7. Remove the bolt.
    8. Detach the guide and disconnect the ground wire.
    9. Disconnect the connector.
    10. Detach the clamp.
    11. Disconnect the lever connector.

      Refer to PROCEDURE - Step 8

  47. REMOVE ECU INTEGRATION BOX RH 

    Refer to PROCEDURE - Step 11

  48. DISCONNECT INSTRUMENT PANEL WIRE 
    1. Remove the 2 bolts.
      GTY1120516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Clamp *b Guide
      Bolt Connector
    2. Detach the guide and disconnect the 2 ground wires.
    3. Disconnect the connector.
    4. Detach the clamp.
  49. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Remove the bolt, nut, screw and No. 1 instrument panel brace sub-assembly.
      GTY869341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
      Screw
  50. REMOVE NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Remove the bolt, nut, screw and No. 2 instrument panel brace sub-assembly.
      GTY871119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
      Screw
  51. DISCONNECT DRAIN COOLER HOSE 
    1. Detach the clamp.
      GTY923521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the drain cooler hose from the cooler unit drain hose grommet.
      NOTE:

      If the cooler unit drain hose grommet was removed from the body, replace it with a new one.

  52. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT ASSEMBLY 
    NOTE:
    • Be sure to support the air conditioning unit assembly when removing it because failure to do so may cause the bracket of the air conditioning unit assembly to break.
    • When disassembling the air conditioning unit assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.
    • Be careful not to damage the internal components of the instrument panel reinforcement assembly with air conditioning unit assembly on the glass etc. Only perform removal after first taking the appropriate actions.
    • Do not allow the instrument panel reinforcement assembly with air conditioning unit assembly to strike the airbag sensor assembly. Doing so may damage the heater case, causing water leaks.
    1. Remove the 3 bolts (A).
      GTY914756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt (A)
    2. Remove the bolt (B).
      GTY876294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt (B) Bolt (C)
      Nut - -
    3. Remove the nut.
    4. Remove the 4 bolts (C).
    5. Remove the instrument panel reinforcement assembly with air conditioning unit assembly from the guide as shown in the illustration.
      NOTE:

      When carrying the instrument panel reinforcement assembly with air conditioning unit assembly, hold the bottom of the assembly. Do not hold the following parts. 

      • Do not hold the air conditioning harness assembly. Otherwise, static electricity from the technician may damage the air conditioning harness assembly.
      • Do not hold the heater core or pipe of the heater radiator unit sub-assembly. Otherwise, the pipe may detach, the clamp may be damaged, or the crimped areas of the heater core and pipe of the heater radiator unit sub-assembly may be damaged, causing coolant to leak.
      • Do not hold the air conditioning radiator damper servo sub-assembly, blower damper servo sub-assembly or link. Otherwise, the servo motor may become misaligned, causing abnormal operation noise, temperature control defects, or air leaks due to sealing defects in the doors.
      • Do not hold the door. Doing so may cause air leaks due to closing defects resulting from excessive opening/closing. Also, keep the door free from oil and grease.
      GTY880945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
  53. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY 

    Refer to PROCEDURE - Step 2

  54. DISCONNECT INSTRUMENT PANEL WIRE 
    1. Disconnect the connector.
      GTY901099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the clamp.
  55. REMOVE ID CODE BOX (IMMOBILIZER CODE ECU) (w/ ID Code Box) 

    Refer to PROCEDURE - Step 7

  56. REMOVE TRANSPONDER KEY ECU (IMMOBILIZER CODE ECU) (w/ Transponder ECU) 

    Refer to PROCEDURE - Step 4

  57. REMOVE AIR CONDITIONING UNIT ASSEMBLY 
    NOTE:
    • Be sure to support the air conditioning unit assembly when removing it because failure to do so may cause the bracket of the air conditioning unit assembly to break.
    • When disassembling the air conditioning unit assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.
    • Be careful not to damage the internal components of the instrument panel reinforcement assembly and air conditioning unit assembly on the glass etc. Only perform removal after first taking the appropriate actions.
    • Store the air conditioning unit assembly in a location free from sand and other foreign matter.
    1. Remove the 3 bolts and air conditioning unit assembly from the instrument panel reinforcement assembly.
      NOTE:

      When carrying the air conditioning unit assembly, hold the bottom of the assembly. Do not hold the following parts. 

      • Do not hold the air conditioning harness assembly. Otherwise, static electricity from the technician may damage the air conditioning harness assembly.
      • Do not hold the heater core or pipe of the heater radiator unit sub-assembly. Otherwise, the pipe may detach, the clamp may be damaged, or the crimped areas of the heater core and pipe of the heater radiator unit sub-assembly may be damaged, causing coolant to leak.
      • Do not hold the air conditioning radiator damper servo sub-assembly, blower damper servo sub-assembly or link. Otherwise, the servo motor may become misaligned, causing abnormal operation noise, temperature control defects, or air leaks due to sealing defects in the doors.
      • Do not hold the door. Doing so may cause air leaks due to closing defects resulting from excessive opening/closing. Also, keep the door free from oil and grease.
      GTY940050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY (for TMC Made) 

    HINT: 

    Perform this procedure only when replacement of the No. 1 air duct sub-assembly is necessary.

    1. Remove the 2 nuts and No. 1 air duct sub-assembly.
      GTY945043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY (for TMMC Made) 

    HINT: 

    • Perform this procedure only when replacement 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).
  60. REMOVE COOLER UNIT DRAIN HOSE GROMMET 

    HINT: 

    Perform this procedure only when replacement of the cooler unit drain hose grommet is necessary.

    1. Remove the cooler unit drain hose grommet.
      GTY945045Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      After removing the cooler unit drain hose grommet, replace it with a new one to prevent water from entering.

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