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Home >> Toyota >> 2025 >> RAV4 Plug-In Hybrid SE >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> Heating / Air Conditioning System - Service Information (1 Of 2) (PHEV) >> Air Conditioning Unit >> Installation [10/2022 - ] >> Procedure

Installation [10/2022 - ]: Procedure

  1. INSTALL COOLER UNIT DRAIN HOSE GROMMET 
    NOTE:

    Perform this procedure only when removal/installation of the cooler unit drain hose grommet is necessary. 

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

    1. Attach one side of the lip on a new cooler unit drain hose grommet (approximately 1/3 of the circumference) to the body hole (fit it to the hole).
      GTY842530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Lip Penetrate Area
    2. Press the entire upper surface of the rib on the cooler unit drain hose grommet, and fit the entire circumference of the lip to the hole.
      NOTE:
      • If the lip on the cooler unit drain hose grommet is not completely fit to the hole, water or noise may enter the interior. When fitting the lip to the hole, make sure that there are no gaps between the lip and body.
      • Do not allow any foreign matter to be trapped between the cooler unit drain hose grommet and installation area, as this may allow noise to enter.
      • Removing the cooler unit drain hose grommet after it has been installed damages the lip due to burrs on the body punch hole (vehicle exterior). This may reduce contact between the edge of the lip and body and cause water to enter the interior. Therefore, do not reuse the cooler unit drain hose grommet.
      • When installing the cooler unit drain hose grommet, do not leave the lip only partially fit to the hole (as in the previous step). This may reduce contact due to lip deformation and cause water to enter the interior. Once you have started to install the part, complete the installation without stopping.
      GTY858698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Rib Upper Surface
  2. INSTALL ID CODE BOX (IMMOBILIZER CODE ECU) 

    Refer to PROCEDURE - Step 1

  3. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY 

    HINT: 

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

    1. Install the No. 1 air duct sub-assembly with the 2 nuts in the order shown in the illustration.
      GTY840269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:
      • Make sure there are no cracks in the No. 1 air duct sub-assembly.
      • Make sure no foreign matter, such as the dash panel insulator, is trapped between the cowl and seal packing.
      • Make sure that the seal packing is securely attached to the cowl on the body. Look from the engine compartment and check that it does not drop down into the fresh air vent. (If foreign matter, such as the dash panel insulator, is trapped or if the seal packing is not securely attached, water or air from gaps may enter the interior.)
  4. INSTALL AIR CONDITIONING UNIT ASSEMBLY 
    NOTE:
    • Be sure to support the air conditioning unit assembly when installing it because failure to do so may cause the bracket of the air conditioning unit assembly to break.
    • When installing 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 installation after first taking the appropriate actions.
    • Do not allow the air conditioning unit assembly to strike the airbag sensor assembly. Doing so may damage the heater case, causing water leaks.
    1. Temporarily set the air conditioning unit assembly nearby the position where it is to be installed.
      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.
    2. Temporarily install the air conditioning unit assembly to the instrument panel reinforcement assembly with the 3 bolts.
      GTY986773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. CONNECT INSTRUMENT PANEL WIRE 
    1. Attach the clamp.
      GTY986194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the connector.
  6. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  7. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT ASSEMBLY 
    NOTE:
    • Be sure to support the air conditioning unit assembly when installing it because failure to do so may cause the bracket of the air conditioning unit assembly to break.
    • When installing 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 installation after first taking the appropriate actions.
    1. Install the instrument panel reinforcement assembly with air conditioning unit assembly to 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.
      NOTE:
      • Do not allow the heater radiator unit sub-assembly heater pipe or connector tube to strike the body.
      • Make sure that both parts are securely installed to the guide.
      GTY987099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction - -
    2. Temporarily install the 4 bolts (C).
      GTY986648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt (B) Bolt (C)
      Nut - -
    3. Temporarily install the bolt (B).
    4. Temporarily install the 3 bolts (A).
      GTY983135Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt (A)
    5. Temporarily install the nut.
    6. Tighten the 4 bolts (C).

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

    7. Tighten the 3 bolts (A).

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

    8. Tighten the bolt (B).

      Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) 

  8. INSTALL HEATER GROMMET 
    1. Install the heater grommet.
      GTY866923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Spool
      NOTE:
      • Push the heater grommet lip seal until it passes over the spools of the heater pipes as shown in the illustration.
      • Make sure that the lip portion of the heater grommet does not sit on top of the spools of the heater pipes.
      • Make sure that there is no gap between the heater grommet and dash panel.
      • Securely fit the heater grommet onto the dash panel. Otherwise, water may enter from the engine room or cause increased noise, vibration or harshness.
  9. CONNECT DRAIN COOLER HOSE 
    NOTE:

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

    1. Connect the drain cooler hose to the cooler unit drain hose grommet.
      GTY986863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      When installing the drain cooler hose, make sure it is not twisted or crushed. Otherwise, water may leak into the interior.

    2. Attach the clamp.
  10. TEMPORARILY INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Temporarily install the No. 2 instrument panel brace sub-assembly with the bolt A, nut and screw.
      GTY985788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt A
      *b Bolt B
      Bolt
      Nut
      Screw
    2. Attach the guide.
    3. Connect the No. 2 instrument panel wire harness with the bolt B.

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

  11. TEMPORARILY INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Temporarily install the No. 1 instrument panel brace sub-assembly with the bolt, nut and screw.
      GTY986158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
      Screw
  12. TIGHTEN INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT ASSEMBLY 
    1. Tighten the 3 bolts, 2 nuts (A), and 2 screws in the order shown in the illustration.

      Bolt 

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

      Nut (A) 

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

      HINT: 

      5 and 6 can be done in either order.

      GTY986293Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt Nut (A)
      Nut (B) Screw
    2. Tighten the nut (B).

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

    3. Tighten the No. 2 instrument panel brace sub-assembly with the bolt.
      GTY855527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

    4. Tighten the No. 1 instrument panel brace sub-assembly with the bolt.
      GTY855525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

  13. CONNECT ENGINE ROOM MAIN WIRE 
    1. Attach the guide.
      GTY985847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the bolt and connect the engine room main wire.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  14. CONNECT INSTRUMENT PANEL WIRE 
    1. Attach the clamp.
      GTY986936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Clamp *b Guide
      Bolt Connector
    2. Connect the connector.
    3. Attach the guide.
    4. Connect the 2 ground wires with the 2 bolts.

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

  15. INSTALL ECU INTEGRATION BOX RH 

    Refer to PROCEDURE - Step 2

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

      Refer to PROCEDURE - Step 1

      GTY986434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Type A *B for Type B
      *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.
      GTY987155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Clamp *b Guide
    8. Attach the guide.
    9. Connect the 2 ground wires with the 2 bolts.

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

    10. Connect the 2 connectors.
      GTY944772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Clamp
      *b Guide
    11. Attach the guide and clamp.
  17. INSTALL POWER DISTRIBUTION BOX ASSEMBLY WITH MAIN BODY ECU 

    Refer to PROCEDURE - Step 2

  18. INSTALL NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  19. INSTALL NO. 2 HEATER TO REGISTER DUCT 
    1. Install the No. 2 heater to register duct with the clip.
      GTY923507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL NO. 1 CONSOLE BOX DUCT 
    1. Install the No. 1 console box duct with the clip.
      GTY923494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL REAR NO. 1 AIR DUCT 
    1. Attach the claw to install the rear No. 1 air duct.
      GTY945002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL REAR NO. 2 AIR DUCT 
    1. Attach the claw.
      GTY923497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the rear No. 2 air duct with the clip.
  23. INSTALL REAR NO. 3 AIR DUCT 

    HINT: 

    Use the same procedure described for the rear No. 1 air duct.

  24. INSTALL REAR NO. 4 AIR DUCT 

    HINT: 

    Use the same procedure described for the rear No. 2 air duct.

  25. INSTALL NO. 3 DASH PANEL INSULATOR PAD 
    1. Attach the guide to install the No. 3 dash panel insulator pad.
      GTY923499Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL FRONT FLOOR FRONT CARPET ASSEMBLY 
    1. Install the front floor front carpet assembly to its original position as shown in the illustration.
      GTY986783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Return to Original Position - -
    2. Attach the guide.
    3. Install the clip.
    4. Install the front floor front carpet assembly to its original position as shown in the illustration.
      GTY986085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Return to Original Position Fastener
    5. Attach the guide.
    6. Attach the 3 fasteners.
    7. Install the clip.
  27. INSTALL FRONT FLOOR CAUTION PLATE COVER 
    1. Attach the clip to install the front floor caution plate cover.
      GTY923492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. While pressing at the positions shown in the illustration, attach the guide and claw.
      GTY939649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Press Position - -
  28. INSTALL ACCELERATOR PEDAL ASSEMBLY 

    Refer to PROCEDURE - Step 1

  29. INSTALL ACCELERATOR PEDAL PAD 

    Refer to PROCEDURE - Step 2

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

      Refer to PROCEDURE - Step 29

    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

  31. INSTALL FRONT SEAT OUTER BELT ASSEMBLY LH 

    Refer to PROCEDURE - Step 31

  32. INSTALL REAR DOOR SCUFF PLATE LH 

    Refer to PROCEDURE - Step 56

  33. INSTALL LOWER CENTER PILLAR GARNISH RH 

    HINT: 

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

  34. INSTALL FRONT SEAT OUTER BELT ASSEMBLY RH 

    HINT: 

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

  35. INSTALL REAR DOOR SCUFF PLATE RH 

    HINT: 

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

  36. INSTALL OUTER LAP BELT ANCHOR COVER 

    Refer to PROCEDURE - Step 33

  37. INSTALL DCM (TELEMATICS TRANSCEIVER) WITH BRACKET 

    Refer to PROCEDURE - Step 6

  38. INSTALL STEERING COLUMN ASSEMBLY 

    Refer to INSTALLATION [10/2022 - ]

  39. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY 

    Refer to INSTALLATION [10/2022 - ]

  40. INSTALL FRONT SEAT ASSEMBLY LH 

    Refer to INSTALLATION [10/2022 - ]

  41. INSTALL FRONT SEAT ASSEMBLY RH 
    1. for Manual Seat:

      Refer to INSTALLATION [10/2022 - ]

    2. for Power Seat:

      Refer to INSTALLATION [10/2022 - ]

  42. 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.
      GTY986827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Hose Clip *2 Inlet Heater Water Hose
      *a View A *b Stopper
      *c Hose Clip Installation Angle (120°) *d Hose Marking Angle (75 to 105°)
      *e 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.
  43. 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.
      GTY985852Courtesy 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 Marking Angle (75 to 105°)
      *e 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.

  44. CONNECT NO. 5 DISCHARGE TUBE 
    1. Remove the vinyl tape wrapped around the connection of the No. 5 discharge tube and the No. 5 discharge tube.
    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioning unit.

      Compressor Oil

      ND-OIL 11 or equivalent

      NOTE:

      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.

    3. Install the O-ring to the No. 5 discharge tube.
      NOTE:

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

    4. Connect the No. 5 discharge tube.
      NOTE:
      • Do not apply excessive force to the No. 5 discharge tube.
      • Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)
      GTY986890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. CONNECT NO. 1 SUCTION TUBE 
    1. Remove the vinyl tape wrapped around the connection of the No. 1 suction tube and No. 1 suction tube.
    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioning unit.

      Compressor Oil

      ND-OIL 11 or equivalent

      NOTE:

      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.

    3. Install the O-ring to the No. 1 suction tube.
      NOTE:

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

    4. Connect the No. 1 suction tube.
      NOTE:
      • Do not apply excessive force to the No. 1 suction tube.
      • 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.
      GTY986007Courtesy 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) 

      GTY986900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSTALL HOLE PLUG 
    1. Install the 2 hole plugs.
      GTY983148Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. 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) 

      GTY983143Courtesy 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
  48. INSTALL COWL VENTILATOR SPLASH SHIELD 
    1. Temporarily install the cowl ventilator splash shield as shown in the illustration.
      GTY1009542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Attach the clip, claw and clamp to install the cowl ventilator splash shield.
      GTY1010167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the connector.
      GTY1009218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to INSTALLATION [06/2020 - ]

  50. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    See step  2

  51. ADD ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 2

  52. INSPECT FOR COOLANT LEAK (for Engine) 

    Refer to PROCEDURE - Step 1

  53. WARM UP COMPRESSOR 

    See step  3

  54. INSPECT FOR REFRIGERANT LEAK 

    See step  4

  55. INITIALIZATION AFTER RECONNECTING BATTERY TERMINAL 

    HINT: 

    When disconnecting and reconnecting the battery, there is an automatic learning function that completes learning when the respective system is used.

    Refer to AUTOMATIC LEARNING CHART [12/2021 - ]

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