Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM10000000258BQ
Model Year Start: 2023 Model: RAV4 HV Prod Date Range: [10/2022 - 10/2023]
Title: HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT (for A25A-FXS): REMOVAL; 2023 MY RAV4 HV [10/2022 - 10/2023]

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed, installed or replaced during the air conditioning unit assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedures

Effect/Inoperative Function when Necessary Procedures are not Performed

Link

*: When performing learning using the Techstream.

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; PARK ASSIST / MONITORING: PARKING SUPPORT BRAKE SYSTEM (for HV Model): CALIBRATION

Disconnect cable from negative (-) auxiliary battery terminal

Perform steering sensor zero point calibration

Lane control system

2022 - 2024 MY RAV4 RAV4 HV [12/2021 -        ]; PRE-COLLISION: PRE-COLLISION SYSTEM: INITIALIZATION

Parking support brake system (for HV model)*

Pre-collision system

Reset back door close position

Power back door system (for HV model)

2019 - 2023 MY RAV4 HV [11/2018 - 10/2023]; DOOR / HATCH: POWER BACK DOOR SYSTEM (for HV Model): INITIALIZATION

Back door lock initialization

Power door lock control system

2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; DOOR LOCK: POWER DOOR LOCK CONTROL SYSTEM: INITIALIZATION

CAUTION:

  • Wear protective gloves. Sharp areas on the parts may injure your hands.
  • There is risk of injury.

NOTICE:

  • After the ignition switch is turned off, the audio and visual system records various types of memory and settings. As a result, after turning the ignition switch off, make sure to wait at least 2 minutes before disconnecting the cable from the negative (-) auxiliary battery terminal.
  • When the cable is disconnected from the negative (-) auxiliary battery terminal and the security lock setting has been enabled, multi-display operations will be disabled upon next startup unless the password is entered. Be sure to check the security lock setting before disconnecting the cable from the negative (-) auxiliary battery terminal.

PROCEDURE

1. PRECAUTION

CAUTION:

Be sure to read precaution thoroughly before servicing.

Click here 2021 - 2024 MY RAV4 RAV4 HV [08/2020 -        ]; SUPPLEMENTAL RESTRAINT SYSTEMS: AIRBAG SYSTEM: PRECAUTION

NOTICE:

  • Make sure to select face mode before disconnecting the cable from the negative (-) auxiliary battery terminal.
  • After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

    Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

3. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

Click here 2019 - 2024 MY RAV4 RAV4 HV [02/2019 -        ]; HEATING / AIR CONDITIONING: REFRIGERANT (for HFO-1234yf(R1234yf)): REPLACEMENT+

4. DRAIN ENGINE COOLANT (for Engine)

Click here 2022 - 2024 MY RAV4 HV [12/2021 -        ]; MAINTENANCE: A25A-FXS COOLANT (for Engine): REPLACEMENT+

5. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; WIPER / WASHER: FRONT WIPER MOTOR: REMOVAL

6. REMOVE COWL VENTILATOR SPLASH SHIELD (for TMC Made)

HINT:

Remove using the same procedure that is performed when replacement of the cowl ventilator splash shield is necessary.

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; WIPER / WASHER: FRONT WIPER MOTOR: REMOVAL+

7. REMOVE COWL VENTILATOR SPLASH SHIELD (for TMMC Made)

HINT:

Use the same procedure described as for the cowl ventilator splash shield (for TMC Made).

8. REMOVE COWL VENTILATOR PANEL SUB-ASSEMBLY

(a) w/ Windshield Deicer System:

(1) Detach the clamp.

(b) Detach the clamp.

Bolt

Nut

(c) Remove the 4 bolts, 4 nuts and cowl ventilator panel sub-assembly.

9. REMOVE HOLE PLUG

(a) Remove the 2 hole plugs.

10. DISCONNECT SUCTION TUBE SUB-ASSEMBLY B (w/o Sub-cool Accelerator)

(a) Remove the bolt.

(b) Rotate the 1-point tightening plate as shown in the illustration.

Rotate in this Direction

(c) Disconnect the suction tube sub-assembly B.

NOTICE:

Do not apply excessive force to the suction tube sub-assembly B.

(d) Remove the O-ring from the suction pipe sub-assembly.

NOTICE:

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

11. DISCONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (w/o Sub-cool Accelerator)

(a) Disconnect the air conditioning tube and accessory assembly.

NOTICE:

Do not apply excessive force to the air conditioning tube and accessory assembly.

(b) Remove the O-ring from the air conditioning tube and accessory assembly.

NOTICE:

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

12. DISCONNECT NO. 2 AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (for TMC Made with Sub-cool Accelerator)

(a) Remove the bolt.

(b) Rotate the 1-point tightening plate as shown in the illustration.

Rotate in this Direction

(c) Disconnect the No. 2 air conditioning tube and accessory assembly.

NOTICE:

Do not apply excessive force to the No. 2 air conditioning tube and accessory assembly.

(d) Remove the 2 O-rings from the No. 2 air conditioning tube and accessory assembly.

NOTICE:

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

13. DISCONNECT 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).

14. DISCONNECT OUTLET HEATER WATER HOSE

(a) Using pliers, grip the claws of the clip and slide the clip to disconnect the outlet heater water hose.

NOTICE:

  • Do not apply excessive force to the outlet heater water hose.
  • Prepare a drain pan or cloth in case the coolant leaks.

15. DISCONNECT INLET HEATER WATER HOSE

(a) Using pliers, grip the claws of the clip and slide the clip to disconnect the inlet heater water hose.

NOTICE:

  • Do not apply excessive force to the inlet heater water hose.
  • Prepare a drain pan or cloth in case the coolant leaks.

16. REMOVE HEATER GROMMET

(a) Remove the heater grommet.

17. REMOVE FRONT SEAT ASSEMBLY LH

(a) for Manual Seat:

Click here 2023 MY RAV4 RAV4 HV [10/2022 - 10/2023]; SEAT: FRONT SEAT ASSEMBLY (for Manual Seat): REMOVAL

(b) for Power Seat:

Click here 2023 MY RAV4 RAV4 HV [10/2022 - 10/2023]; SEAT: FRONT SEAT ASSEMBLY (for Power Seat): REMOVAL

18. REMOVE FRONT SEAT ASSEMBLY RH

HINT:

Use the same procedure described for the LH side.

19. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY

Click here 2023 - 2024 MY RAV4 RAV4 HV [10/2022 -        ]; INTERIOR PANELS / TRIM: INSTRUMENT PANEL SAFETY PAD: REMOVAL

20. REMOVE STEERING COLUMN ASSEMBLY

Click here 2023 MY RAV4 RAV4 HV [10/2022 - 10/2023]; STEERING COLUMN: STEERING COLUMN ASSEMBLY: REMOVAL

21. REMOVE DCM (TELEMATICS TRANSCEIVER) WITH BRACKET (w/ DCM)

Click here 2023 - 2024 MY RAV4 RAV4 HV [10/2022 -        ]; CELLULAR COMMUNICATION: DCM(TELEMATICS TRANSCEIVER): REMOVAL+

22. REMOVE OUTER LAP BELT ANCHOR COVER

Click here 2021 - 2024 MY RAV4 RAV4 HV [08/2020 -        ]; INTERIOR PANELS / TRIM: ROOF HEADLINING: REMOVAL+

23. REMOVE REAR DOOR SCUFF PLATE LH

Click here 2021 - 2024 MY RAV4 RAV4 HV [08/2020 -        ]; INTERIOR PANELS / TRIM: ROOF HEADLINING: REMOVAL+

24. REMOVE FRONT SEAT OUTER BELT ASSEMBLY LH

Click here 2021 - 2024 MY RAV4 RAV4 HV [08/2020 -        ]; INTERIOR PANELS / TRIM: ROOF HEADLINING: REMOVAL+

25. REMOVE LOWER CENTER PILLAR GARNISH LH

(a) Remove the rear side of the front door opening trim weatherstrip LH so that the lower center pillar garnish LH can be removed.

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; DOOR / HATCH: FRONT DOOR OPENING TRIM WEATHERSTRIP: REMOVAL+

(b) Remove the front side of the rear door opening trim weatherstrip LH so that the lower center pillar garnish LH can be removed.

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; DOOR / HATCH: REAR DOOR OPENING TRIM WEATHERSTRIP: REMOVAL+

(c) Remove the lower center pillar garnish LH.

Click here 2021 - 2024 MY RAV4 RAV4 HV [08/2020 -        ]; INTERIOR PANELS / TRIM: ROOF HEADLINING: REMOVAL+

26. REMOVE REAR DOOR SCUFF PLATE RH

HINT:

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

27. REMOVE FRONT SEAT OUTER BELT ASSEMBLY RH

HINT:

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

28. REMOVE LOWER CENTER PILLAR GARNISH RH

HINT:

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

29. REMOVE ACCELERATOR PEDAL PAD

Click here 2019 - 2024 MY RAV4 HV [11/2018 -        ]; HYBRID / BATTERY CONTROL: ACCELERATOR PEDAL SENSOR: REMOVAL+

30. REMOVE ACCELERATOR PEDAL ASSEMBLY

Click here 2019 - 2024 MY RAV4 HV [11/2018 -        ]; HYBRID / BATTERY CONTROL: ACCELERATOR PEDAL SENSOR: REMOVAL+

31. REMOVE FRONT FLOOR CAUTION PLATE COVER (w/ Cover)

(a) Place your fingers at the positions shown in the illustration, detach the claw and guide and open the front floor caution plate cover.

Place Finger Here

(b) Detach the clip and remove the front floor caution plate cover.

32. REMOVE FRONT FLOOR FRONT CARPET ASSEMBLY

(a) Remove the clip.

Fold Back

Fastener

(b) Detach the guide.

(c) Detach each fastener and fold back the front floor front carpet assembly as shown in the illustration.

(d) Remove the clip.

Fold Back

-

-

(e) Detach the guide and fold back the front floor front carpet assembly as shown in the illustration.

33. REMOVE NO. 3 DASH PANEL INSULATOR PAD

(a) Detach the guide and remove the No. 3 dash panel insulator pad.

34. REMOVE REAR NO. 4 AIR DUCT (for TMC Made)

(a) Remove the clip.

(b) Detach the claw and remove the rear No. 4 air duct.

35. REMOVE 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).

36. REMOVE REAR NO. 3 AIR DUCT (for TMC Made)

(a) Detach the claw and remove the rear No. 3 air duct.

37. REMOVE 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).

38. REMOVE 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).

39. REMOVE 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).

40. REMOVE REAR NO. 1 AIR DUCT

HINT:

Use the same procedure described as for the rear No. 3 air duct (for TMC Made).

41. REMOVE NO. 1 CONSOLE BOX DUCT

(a) Remove the clip and No. 1 console box duct.

42. REMOVE NO. 2 HEATER TO REGISTER DUCT SUB-ASSEMBLY

(a) Remove the clip and No. 2 heater to register duct sub-assembly.

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

Click here 2023 MY RAV4 RAV4 HV [10/2022 - 10/2023]; POWER DISTRIBUTION: MAIN BODY ECU: REMOVAL+

44. REMOVE 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).

45. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU

Click here 2023 MY RAV4 RAV4 HV [10/2022 - 10/2023]; POWER DISTRIBUTION: MAIN BODY ECU: REMOVAL+

46. DISCONNECT INSTRUMENT PANEL WIRE

(a) Disconnect the 2 connectors.

*a

Clamp

*b

Guide

(b) Detach the clamp and guide.

(c) Remove the 3 bolts.

*a

Clamp

*b

Guide

(d) Detach the guide and disconnect the 3 ground wires.

(e) Detach the clamp.

(f) Remove the nut.

*A

for Type A

*B

for Type B

*a

Clamp

*b

Guide

Bolt

Nut

Connector

Lever Connector

(g) Remove the bolt.

(h) Detach the guide and disconnect the ground wire.

(i) Disconnect the connector.

(j) Detach the clamp.

(k) Disconnect the lever connector.

Click here 2023 MY RAV4 RAV4 HV [10/2022 - 10/2023]; SUPPLEMENTAL RESTRAINT SYSTEMS: CENTER AIRBAG SENSOR ASSEMBLY: REMOVAL+

47. REMOVE ECU INTEGRATION BOX RH

Click here 2023 MY RAV4 RAV4 HV [10/2022 - 10/2023]; NETWORKING: NETWORK GATEWAY ECU: REMOVAL+

48. DISCONNECT INSTRUMENT PANEL WIRE

(a) Remove the 2 bolts.

*a

Clamp

*b

Guide

Bolt

Connector

(b) Detach the guide and disconnect the 2 ground wires.

(c) Disconnect the connector.

(d) Detach the clamp.

49. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

(a) Remove the bolt, nut, screw and No. 1 instrument panel brace sub-assembly.

Bolt

Nut

Screw

50. REMOVE NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

(a) Remove the bolt, nut, screw and No. 2 instrument panel brace sub-assembly.

Bolt

Nut

Screw

51. DISCONNECT DRAIN COOLER HOSE

(a) Detach the clamp.

(b) Disconnect the drain cooler hose from the cooler unit drain hose grommet.

NOTICE:

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

52. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT ASSEMBLY

NOTICE:

  • 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.

(a) Remove the 3 bolts (A).

Bolt (A)

(b) Remove the bolt (B).

Bolt (B)

Bolt (C)

Nut

-

-

(c) Remove the nut.

(d) Remove the 4 bolts (C).

(e) Remove the instrument panel reinforcement assembly with air conditioning unit assembly from the guide as shown in the illustration.

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.

Remove in this Direction

-

-

53. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY

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

54. DISCONNECT INSTRUMENT PANEL WIRE

(a) Disconnect the connector.

(b) Detach the clamp.

55. REMOVE ID CODE BOX (IMMOBILIZER CODE ECU) (w/ ID Code Box)

Click here 2023 MY RAV4 RAV4 HV [10/2022 - 10/2023]; THEFT DETERRENT / KEYLESS ENTRY: ID CODE BOX: REMOVAL+

56. REMOVE TRANSPONDER KEY ECU (IMMOBILIZER CODE ECU) (w/ Transponder ECU)

Click here 2023 MY RAV4 RAV4 HV [10/2022 - 10/2023]; THEFT DETERRENT / KEYLESS ENTRY: TRANSPONDER KEY ECU: REMOVAL+

57. REMOVE AIR CONDITIONING UNIT ASSEMBLY

NOTICE:

  • 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.

(a) Remove the 3 bolts and air conditioning unit assembly from the instrument panel reinforcement assembly.

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.

58. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY (for TMC Made)

HINT:

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

(a) Remove the 2 nuts and No. 1 air duct sub-assembly.

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

HINT:

  • Perform this procedure only when replacement 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).

60. REMOVE COOLER UNIT DRAIN HOSE GROMMET

HINT:

Perform this procedure only when replacement of the cooler unit drain hose grommet is necessary.

(a) Remove the cooler unit drain hose grommet.

NOTICE:

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