Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000001QMYQ
Model Year Start: 2021 Model: RAV4 HV Prod Date Range: [08/2020 -           ]
Title: HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT (for A25A-FXS): DISASSEMBLY; 2021 - 2024 MY RAV4 HV [08/2020 -        ]

DISASSEMBLY

PROCEDURE

1. REMOVE BLOWER ASSEMBLY

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; HEATING / AIR CONDITIONING: BLOWER UNIT: REMOVAL

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

(a) Detach the claw and remove the No. 2 air duct sub-assembly.

3. REMOVE NO. 4 AIR DUCT SUB-ASSEMBLY (for TMMC Made)

HINT:

Use the same procedure described as for the No. 2 air duct sub-assembly (for TMC Made).

4. REMOVE ASPIRATOR (for TMC Made)

(a) Detach the guide.

(b) Detach the claw and remove the aspirator.

5. REMOVE ASPIRATOR PIPE (for TMMC Made)

HINT:

Use the same procedure described as for the aspirator (for TMC Made).

6. REMOVE COOLER THERMISTOR (ROOM TEMPERATURE SENSOR)

(a) Remove the cooler thermistor (room temperature sensor).

7. REMOVE DRAIN COOLER HOSE

(a) Remove the drain cooler hose.

8. REMOVE AIR CONDITIONING HARNESS ASSEMBLY

(a) Disconnect each connector.

*A

w/ Driver Seat Centralized Control

-

-

*a

Clamp

*b

Guide

(b) Detach the clamp and guide and remove the air conditioning harness assembly.

9. REMOVE NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY

(a) Remove the 3 screws.

(b) Detach the guide and remove the No. 1 air conditioning radiator damper servo sub-assembly.

10. REMOVE NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY

(a) Remove the 2 screws.

(b) Detach the guide and remove the No. 2 air conditioning radiator damper servo sub-assembly.

11. REMOVE NO. 3 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (w/ Driver Seat Centralized Control)

(a) Remove the 2 screws.

(b) Detach the guide and remove the No. 3 air conditioning radiator damper servo sub-assembly.

12. REMOVE HEATER PIPE GROMMET

(a) Remove the heater pipe grommet.

13. REMOVE HEATER CLAMP

(a) Detach the claw and remove the heater clamp.

14. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY

(a) Remove the heater radiator unit sub-assembly as shown in the illustration.

NOTICE:

Prepare a drain pan or cloth in case the coolant leaks.

Remove in this Direction

15. REMOVE COOLING UNIT PARTS

(a) Remove the cooling unit parts.

*A

for Type A

*B

for Type B

16. REMOVE COOLER EXPANSION VALVE

(a) Using a 4 mm hexagon socket wrench, remove the 2 hexagon bolts and cooler expansion valve.

*A

for Type A

*B

for Type B

(b) Remove the 2 O-rings from the No. 1 cooler evaporator sub-assembly.

NOTICE:

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

17. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY

(a) Remove the 2 screws.

*a

No. 1 Cooler Thermistor Lead Wire

-

-

Detach lead wire from guide

-

-

(b) Detach the claw and guide, and then while detaching the lead wire of the No. 1 cooler thermistor from the guide, separate the upper heater case with No. 1 cooler evaporator sub-assembly from the lower heater case as shown in the illustration.

(c) Detach the guide.

*A

for Type A

*B

for Type B

(d) Remove the No. 1 cooler evaporator sub-assembly with No. 1 cooler thermistor from the upper heater case.

NOTICE:

When the No. 1 cooler evaporator sub-assembly is removed, make sure to install a new one. The No. 1 cooler evaporator sub-assembly cannot be reused.

18. REMOVE NO. 1 COOLER THERMISTOR

Click here 2019 - 2024 MY RAV4 RAV4 HV [02/2019 -        ]; HEATING / AIR CONDITIONING: FRONT EVAPORATOR TEMPERATURE SENSOR: REMOVAL+

19. REMOVE HEATER COVER (for TMC Made)

Perform this procedure only when removal/installation of the heater cover is necessary.

NOTICE:

If the heater cover is removed, the heater cover itself can be reused, but the air conditioning radiator assembly cannot be reused. After the heater cover is installed, the support (triangular rib) on the air conditioning radiator assembly is crushed. Therefore, if the air conditioning radiator assembly is reused, abnormal noise may occur due to looseness.

(a) Remove the screw.

Remove in this Direction

(b) Remove the heater cover as shown in the illustration.

20. REMOVE NO. 2 HEATER COVER (for TMMC Made)

Perform this procedure only when removal/installation of the No. 2 heater cover is necessary.

NOTICE:

If the No. 2 heater cover is removed, the No. 2 heater cover itself can be reused, but the air conditioning radiator assembly cannot be reused. After the No. 2 heater cover is installed, the support (triangular rib) on the air conditioning radiator assembly is crushed. Therefore, if the air conditioning radiator assembly is reused, abnormal noise may occur due to looseness.

HINT:

Use the same procedure described as for the heater cover (for TMC Made).