HEATING / AIR CONDITIONING: COMPRESSOR (for A25A-FXS): INSTALLATION; 2021 - 2023 MY RAV4 HV [08/2020

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM100000001QI80
Model Year Start: 2021	Model: RAV4 HV	Prod Date Range: [08/2020 - 10/2023]
Title: HEATING / AIR CONDITIONING: COMPRESSOR (for A25A-FXS): INSTALLATION; 2021 - 2023 MY RAV4 HV [08/2020 - 10/2023]

INSTALLATION

PROCEDURE

1. ADJUST COMPRESSOR OIL

(a) When replacing the compressor with motor assembly with a new one, gradually discharge the inert gas from the service valve, and drain the following amount of oil from the new compressor with motor assembly before installation.

Standard:

(Oil capacity inside the new compressor with motor assembly: 120 to 135 cc (4.06 to 4.56 fl. oz)) - (Remaining oil amount in the removed compressor with motor assembly) = (Oil amount to be removed from the new compressor with motor assembly)

NOTICE:

If a new compressor with motor assembly is installed without removing some oil, there will be too much oil in the system due to the oil remaining in the pipes of the vehicle. Excessive oil in the system prevents heat exchange in the refrigeration cycle and causes ineffective cooling.
If the amount of oil remaining in the old compressor with motor assembly is too small, check the air conditioning system for oil leaks.
Be sure to use ND-OIL 11 or equivalent compressor oil. If any compressor oil other than ND-OIL 11 is used, compressor with motor assembly insulation performance may decrease, resulting in leakage of electric power.

2. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY

(a) Remove the insulating tape from the connector (B).

	Connector (B)
	Slide
	Green-colored Lock

(b) Connect the connector (B) and slide the green-colored lock as shown in the illustration to securely lock it.

CAUTION:

Make sure to wear insulated gloves.

NOTICE:

Make sure that the connector is connected securely.

(c) Using an E8 "TORX" socket wrench, temporarily install the compressor with motor assembly with the 2 stud bolts and bolt.

	Bolt
	Stud Bolt

Torque:

Stud Bolt :

5.0 N·m {51 kgf·cm, 44 in·lbf}

(d) Install the compressor with motor assembly with the bolt and 2 nuts.

	Bolt
	Nut

Torque:

24.5 N·m {250 kgf·cm, 18 ft·lbf}

HINT:

Tighten the bolts and nuts in the order shown in the illustration, or temporarily install 3 of them, and then tighten them in the order 1, 2 and 3.

(e) Connect the connector (A).

Connector (A)

3. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

(a) Remove the vinyl tape wrapped around the connection of the No. 1 cooler refrigerant discharge hose and No. 1 cooler refrigerant discharge hose.

(b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor with motor assembly.

Compressor Oil:

ND-OIL 11 or equivalent

NOTICE:

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.

NOTICE:

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

(d) Connect the No. 1 cooler refrigerant discharge hose with the bolt.

Torque:

9.8 N·m {100 kgf·cm, 87 in·lbf}

NOTICE:

Do not apply excessive force to the No. 1 cooler refrigerant discharge hose.
Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)

4. CONNECT SUCTION HOSE SUB-ASSEMBLY

(a) Remove the vinyl tape wrapped around the connection of the suction hose sub-assembly and suction hose sub-assembly.

(b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor with motor assembly.

Compressor Oil:

ND-OIL 11 or equivalent

NOTICE:

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

(d) Connect the suction hose sub-assembly.

Torque:

9.8 N·m {100 kgf·cm, 87 in·lbf}

NOTICE:

Do not apply excessive force to the suction hose sub-assembly.
Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)

5. INSTALL FRONT FENDER LINER RH

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6. INSTALL FRONT FENDER APRON SEAL RH (for TMC Made)

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7. INSTALL FRONT FENDER APRON SEAL RH (for TMMC Made)

HINT:

Use the same procedure described as for the front fender apron seal RH (for TMC Made).

8. INSTALL FRONT FENDER MUDGUARD RH (w/ Mudguard)

(a) for Short Type:

HINT:

Use the same procedure described as for the LH side.

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(b) for Long Type:

HINT:

Use the same procedure described as for the LH side.

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9. INSTALL NO. 1 ENGINE UNDER COVER

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10. INSTALL FRONT FENDER FRONT SPLASH SHIELD LH

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11. INSTALL FRONT FENDER FRONT SPLASH SHIELD RH

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12. INSTALL FRONT FENDER MOULDING SUB-ASSEMBLY RH (for TMC Made)

HINT:

Use the same procedure described as for the LH side.

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13. INSTALL FRONT FENDER FRONT OUTSIDE MOULDING RH (for TMMC Made)

HINT:

Use the same procedure described as for the front fender moulding sub-assembly RH (for TMC Made).

14. INSTALL FRONT WHEEL RH

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15. INSTALL SERVICE PLUG GRIP

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16. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

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17. WARM UP COMPRESSOR

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18. INSPECT FOR REFRIGERANT LEAK

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