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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 (4 Of 5) >> AIR CONDITIONING UNIT (for A25A-FKS) >> Installation [08/2020 - 10/2022] >> Procedure

Installation [08/2020 - 10/2022]: Procedure

  1. INSTALL COOLER UNIT DRAIN HOSE GROMMET 

    Refer to PROCEDURE - Step 1 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 1 [12/2021 - 10/2022]

  2. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY (for TMC Made) 

    Refer to PROCEDURE - Step 2 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 2 [12/2021 - 10/2022]

  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 

    Refer to PROCEDURE - Step 4 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 4 [12/2021 - 10/2022]

  5. INSTALL ID CODE BOX (IMMOBILIZER CODE ECU) (w/ ID Code Box) 

    Refer to PROCEDURE - Step 1

  6. INSTALL TRANSPONDER KEY ECU (IMMOBILIZER CODE ECU) (w/ Transponder ECU) 

    Refer to PROCEDURE - Step 1

  7. CONNECT INSTRUMENT PANEL WIRE 
    1. Attach the clamp.
      GTY877940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A w/ ECU - -
    2. Connect the connector.
  8. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  9. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT ASSEMBLY 

    Refer to PROCEDURE - Step 9 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 9 [12/2021 - 10/2022]

  10. INSTALL HEATER GROMMET 

    Refer to PROCEDURE - Step 10 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 10 [12/2021 - 10/2022]

  11. CONNECT DRAIN COOLER HOSE 

    Refer to PROCEDURE - Step 11 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 11 [12/2021 - 10/2022]

  12. TEMPORARILY INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 12 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 12 [12/2021 - 10/2022]

  13. TEMPORARILY INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 13 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 13 [12/2021 - 10/2022]

  14. TIGHTEN INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT ASSEMBLY 

    Refer to PROCEDURE - Step 14 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 14 [12/2021 - 10/2022]

  15. CONNECT INSTRUMENT PANEL WIRE 

    Refer to PROCEDURE - Step 15 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 17 [12/2021 - 10/2022]

  16. INSTALL ECU INTEGRATION BOX RH 

    Refer to PROCEDURE - Step 2

  17. CONNECT INSTRUMENT PANEL WIRE 
    1. Connect the lever connector.

      Refer to PROCEDURE - Step 1

      GTY857758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Type A *B for Type B
      *C for Automatic Air Conditioning System - -
      *a Clamp *b Guide
      Bolt Nut
      Connector Lever Connector
    2. Attach the clamp.
    3. Connect the connector.
    4. Attach the guide.
    5. Connect the ground wire with the bolt.

      Torque: 8.5 N.m (87 kgf/cm, 75 in.lbf) 

    6. Install the nut.

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

    7. Attach the clamp.
      GTY879846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Clamp *b Guide
    8. Attach the guide.
    9. Connect the 3 ground wires with the 3 bolts.

      Torque: 8.5 N.m (87 kgf/cm, 75 in.lbf) 

    10. Connect the 2 connectors.
      GTY874951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Clamp
      *b Guide
    11. Attach the guide and clamp.
  18. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU 

    Refer to PROCEDURE - Step 2

  19. INSTALL NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY (for TMC Made) 

    Refer to PROCEDURE - Step 3

  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 

    Refer to PROCEDURE - Step 21 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 21 [12/2021 - 10/2022]

  22. INSTALL NO. 1 CONSOLE BOX DUCT (w/ Rear Register Duct) 

    Refer to PROCEDURE - Step 22 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 22 [12/2021 - 10/2022]

  23. INSTALL REAR NO. 3 AIR DUCT (for TMC Made) 

    Refer to PROCEDURE - Step 23 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 23 [12/2021 - 10/2022]

  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) 

    Refer to PROCEDURE - Step 25 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 25 [12/2021 - 10/2022]

  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 

    Refer to PROCEDURE - Step 30 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 30 [12/2021 - 10/2022]

  31. INSTALL FRONT FLOOR FRONT CARPET ASSEMBLY 

    Refer to PROCEDURE - Step 31 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 31 [12/2021 - 10/2022]

  32. INSTALL FRONT FLOOR CAUTION PLATE COVER (w/ Cover) 

    Refer to PROCEDURE - Step 32 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 32 [12/2021 - 10/2022]

  33. INSTALL ACCELERATOR PEDAL ASSEMBLY 

    Refer to PROCEDURE - Step 1

  34. INSTALL ACCELERATOR PEDAL PAD 

    Refer to PROCEDURE - Step 2

  35. INSTALL LOWER CENTER PILLAR GARNISH LH 
    1. Install the lower center pillar garnish LH.

      Refer to PROCEDURE - Step 31

    2. Return the front door opening trim weatherstrip LH to its original position.

      Refer to PROCEDURE - Step 1

    3. Return the rear door opening trim weatherstrip LH to its original position.

      Refer to PROCEDURE - Step 1

  36. INSTALL FRONT SEAT OUTER BELT ASSEMBLY LH 

    Refer to PROCEDURE - Step 33

  37. INSTALL REAR DOOR SCUFF PLATE LH 

    Refer to PROCEDURE - Step 58

  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 

    Refer to PROCEDURE - Step 35

  42. INSTALL NAVIGATION ECU WITH BRACKET (w/ Navigation System) 
    1. w/o DCM:

      Refer to PROCEDURE - Step 7

    2. w/ DCM:

      Refer to PROCEDURE - Step 8

  43. INSTALL DCM (TELEPHONE TRANSCEIVER ASSEMBLY) WITH BRACKET (w/ DCM) 
    1. w/ Navigation System:

      Refer to PROCEDURE - Step 8

    2. w/o Navigation System:

      Refer to PROCEDURE - Step 9

  44. INSTALL STEERING COLUMN ASSEMBLY 

    Refer to INSTALLATION [11/2018 - ]

  45. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY 

    Refer to INSTALLATION [08/2020 - 10/2022]

  46. INSTALL FRONT SEAT ASSEMBLY LH 
    1. for Manual Seat:

      Refer to INSTALLATION [08/2020 - ]

    2. for Power Seat:

      Refer to INSTALLATION [08/2020 - 12/2021] , or refer to INSTALLATION [12/2021 - ]

  47. INSTALL FRONT SEAT ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

  48. CONNECT INLET HEATER WATER HOSE 
    1. Connect the inlet heater water hose as shown in the illustration.
      NOTE:
      • 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.
      GTY893984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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.))
    2. Make sure to install the hose clip within the range shown in the illustration.
  49. CONNECT OUTLET HEATER WATER HOSE 
    1. Connect the outlet heater water hose as shown in the illustration.
      NOTE:
      • 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.
      GTY915793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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.))
    2. Make sure to install the hose clip within the range shown in the illustration.
      NOTE:

      Make sure that the hose clamps do not contact each other.

  50. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (w/o Sub-cool Accelerator) 
    1. Remove the vinyl tape wrapped around the connection of the air conditioning tube and accessory assembly and the air conditioning tube and accessory assembly.
    2. 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

    3. Install the O-ring to the air conditioning tube and accessory assembly.
      NOTE:

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

    4. Connect the air conditioning tube and accessory assembly.
      NOTE:
      • 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) 
    1. Remove the vinyl tape wrapped around the connection of the suction pipe sub-assembly and suction pipe sub-assembly.
    2. 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

    3. Install the O-ring to the suction pipe sub-assembly.
      NOTE:

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

    4. Connect the suction pipe sub-assembly.
      NOTE:
      • 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)
    5. Rotate the 1-point tightening plate as shown in the illustration.
      GTY922098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Rotate in this Direction
    6. Insert the tube joint into the fitting hole securely and install the bolt.

      Torque: 9.8 N.m (100 kgf/cm, 87 in.lbf) 

      GTY839531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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) 
    1. 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.
    2. 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

    3. Install the 2 O-rings to the No. 2 air conditioning tube and accessory assembly.
      NOTE:

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

    4. Connect the No. 2 air conditioning tube and accessory assembly.
      NOTE:
      • 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)
    5. Rotate the 1-point tightening plate as shown in the illustration.
      GTY926435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Rotate in this Direction
    6. Insert the tube joint into the fitting hole securely and install the bolt.

      Torque: 9.8 N.m (100 kgf/cm, 87 in.lbf) 

      GTY839329Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 

    Refer to PROCEDURE - Step 53 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 54 [12/2021 - 10/2022]

  56. INSTALL COWL VENTILATOR PANEL SUB-ASSEMBLY 
    1. Install the cowl ventilator panel sub-assembly with the 4 bolts and 4 nuts.

      Bolt 

      Torque: 5.5 N.m (56 kgf/cm, 49 in.lbf) 

      Nut 

      Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

      GTY871117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt Nut
    2. Attach the clamp.
    3. w/ Windshield Deicer System:
      1. Attach the clamp.
        GTY930008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. INSTALL COWL VENTILATOR SPLASH SHIELD (for TMC Made) 

    Refer to PROCEDURE - Step 2

  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 

    Refer to INSTALLATION [11/2018 - ]

  60. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 2

  61. ADD ENGINE COOLANT 

    Refer to PROCEDURE - Step 2

  62. INSPECT FOR COOLANT LEAK 

    Refer to PROCEDURE - Step 1

  63. WARM UP ENGINE 

    Refer to PROCEDURE - Step 4

  64. INSPECT FOR REFRIGERANT LEAK 

    Refer to PROCEDURE - Step 5

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