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Home >> Toyota >> 2025 >> RAV4 Plug-In Hybrid XSE >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> Heating / Air Conditioning System - Service Information (1 Of 2) (PHEV) >> Air Conditioning Unit >> Removal [06/2020 - 12/2021] >> Procedure

Removal [06/2020 - 12/2021]: Procedure

  1. PRECAUTION 
    WARNING:

    Be sure to read precaution thoroughly before servicing.

    GTY824211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Refer to PRECAUTION [06/2020 - 10/2022]

    NOTE:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal.

    Refer to BEFORE DISCONNECTING BATTERY [06/2020 - 10/2022]

  2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  3. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 

    See step  1

  4. DRAIN ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 1

  5. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [06/2020 - ]

  6. REMOVE COWL VENTILATOR SPLASH SHIELD 
    1. Disconnect the connector.
      GTY1009218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the clamp and claw.
      GTY1009209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Pull the cowl ventilator splash shield in the direction of the arrow indicated in the illustration to detach the clip.
      GTY1009963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction (1)
      Remove in this Direction (2)
    4. Pull out the cowl ventilator splash shield in the direction of the arrow indicated in the illustration to remove it.
    5. Using a clip remover with its tip wrapped with protective tape, detach the clip remaining on the vehicle and install the cowl ventilator splash shield.
      GTY1009506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Protective Tape
  7. 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.
      GTY983143Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt Nut
    3. Remove the 4 bolts, 4 nuts and cowl ventilator panel sub-assembly.
  8. REMOVE HOLE PLUG 
    1. Remove the 2 hole plugs.
      GTY855519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. DISCONNECT NO. 1 SUCTION TUBE 
    1. Remove the bolt.
      GTY986900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Rotate the 1-point tightening plate as shown in the illustration.
      GTY986275Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Rotate in this Direction
    3. Disconnect the No. 1 suction tube.
      GTY986896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not apply excessive force to the No. 1 suction tube.

    4. Remove the O-ring from the No. 1 suction tube.
      NOTE:

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

  10. DISCONNECT NO. 5 DISCHARGE TUBE 
    1. Disconnect the No. 5 discharge tube.
      GTY986890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not apply excessive force to the No. 5 discharge tube.

    2. Remove the O-ring from the No. 5 discharge tube.
      NOTE:

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

  11. 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.
      GTY985792Courtesy 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.
  12. 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.
      GTY986888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE HEATER GROMMET 
    1. Remove the heater grommet.
      GTY986889Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE FRONT SEAT ASSEMBLY LH 

    Refer to REMOVAL [06/2020 - 12/2021]

  15. REMOVE FRONT SEAT ASSEMBLY RH 
    1. for Manual Seat:

      Refer to REMOVAL [06/2020 - 12/2021]

    2. for Power Seat:

      Refer to REMOVAL [06/2020 - 12/2021]

  16. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY 

    Refer to REMOVAL [06/2020 - 12/2021]

  17. REMOVE STEERING COLUMN ASSEMBLY 

    Refer to REMOVAL [06/2020 - 12/2021]

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

    Refer to PROCEDURE - Step 5

  19. 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

  20. REMOVE OUTER LAP BELT ANCHOR COVER 

    Refer to PROCEDURE - Step 31

  21. REMOVE REAR DOOR SCUFF PLATE LH 

    Refer to PROCEDURE - Step 7

  22. REMOVE FRONT SEAT OUTER BELT ASSEMBLY LH 

    Refer to PROCEDURE - Step 32

  23. 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 34

  24. REMOVE REAR DOOR SCUFF PLATE RH 

    HINT: 

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

  25. REMOVE FRONT SEAT OUTER BELT ASSEMBLY RH 

    HINT: 

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

  26. REMOVE LOWER CENTER PILLAR GARNISH RH 

    HINT: 

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

  27. REMOVE ACCELERATOR PEDAL PAD 

    Refer to PROCEDURE - Step 5

  28. REMOVE ACCELERATOR PEDAL ASSEMBLY 

    Refer to PROCEDURE - Step 6

  29. REMOVE FRONT FLOOR CAUTION PLATE 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.
      GTY986386Courtesy 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
  30. REMOVE FRONT FLOOR FRONT CARPET ASSEMBLY 
    1. Remove the clip.
      GTY985824Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fold Back Fastener
    2. Detach the guide.
    3. Detach 3 fasteners and fold back the front floor front carpet assembly as shown in the illustration.
    4. Remove the clip.
      GTY987224Courtesy 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.
  31. REMOVE NO. 3 DASH PANEL INSULATOR PAD 
    1. Detach the guide and remove the No. 3 dash panel insulator pad.
      GTY986878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE REAR NO. 2 AIR DUCT 
    1. Remove the clip.
      GTY923497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the claw and remove the rear No. 2 air duct.
  33. REMOVE REAR NO. 1 AIR DUCT 
    1. Detach the claw and remove the rear No. 1 air duct.
      GTY945002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE REAR NO. 4 AIR DUCT 

    HINT: 

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

  35. REMOVE REAR NO. 3 AIR DUCT 

    HINT: 

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

  36. REMOVE NO. 1 CONSOLE BOX DUCT 
    1. Remove the clip and No. 1 console box duct.
      GTY923494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE NO. 2 HEATER TO REGISTER DUCT 
    1. Remove the clip and No. 2 heater to register duct.
      GTY923507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  39. REMOVE POWER DISTRIBUTION BOX ASSEMBLY WITH MAIN BODY ECU 

    Refer to PROCEDURE - Step 4

  40. 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 2 bolts.
      GTY987154Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Clamp *b Guide
    4. Detach the guide and disconnect the 2 ground wires.
    5. Detach the clamp.
    6. Remove the nut.
      GTY986428Courtesy 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 5

  41. DISCONNECT ENGINE ROOM MAIN WIRE 
    1. Remove the bolt.
      GTY985847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the guide and disconnect the engine room main wire.
  42. REMOVE ECU INTEGRATION BOX RH 

    Refer to PROCEDURE - Step 7

  43. DISCONNECT INSTRUMENT PANEL WIRE 
    1. Remove the 2 bolts.
      GTY986932Courtesy 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.
  44. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Remove the bolt, nut, screw and No. 1 instrument panel brace sub-assembly.
      GTY986157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
      Screw
  45. REMOVE NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Remove the bolt B.
      GTY985788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt A
      *b Bolt B
      Bolt
      Nut
      Screw
    2. Detach the guide and disconnect the No. 2 instrument panel wire.
    3. Remove the bolt A, nut, screw and No. 2 instrument panel brace sub-assembly.
  46. DISCONNECT DRAIN COOLER HOSE 
    1. Detach the clamp.
      GTY986863Courtesy 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.

  47. 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).
      GTY983135Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt (A)
    2. Remove the bolt (B).
      GTY986649Courtesy 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.
      GTY987212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
  48. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY 

    Refer to PROCEDURE - Step 2

  49. DISCONNECT INSTRUMENT PANEL WIRE 
    1. Disconnect the connector.
      GTY986194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the clamp.
  50. 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.
      GTY986773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY 

    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
  52. REMOVE ID CODE BOX (IMMOBILIZER CODE ECU) 

    Refer to PROCEDURE - Step 3

  53. 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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