Air Conditioning: Removal & Installation Toyota RAV4 III

REMOVAL

1. REMOVE BLOWER ASSEMBLY Remove the blower (see «REMOVAL»(ref-265087-S33385029552007092000000) ).
2. REMOVE AIR INLET CONTROL SERVO MOTOR (See «REMOVAL»(ref-265087-S27108290742007092000000) )

Scheme 261

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Scheme 264

1. INSPECT AIR INLET CONTROL SERVO MOTOR (For Automatic Air Conditioning System) Inspect the servo motor operation. Connect the positive (+) lead from the battery to terminal 4 and negative (-) lead to terminal 5, and then check that the arm turns to the "FRESH" side smoothly. Connect the positive (+) lead from the battery to terminal 5 and negative (-) lead to terminal 4, and then check that the arm turns to the "RECIRCULATION" side smoothly. If the operation is not as specified, replace the air inlet control servo motor.
2. INSPECT AIR INLET CONTROL SERVO MOTOR (For Manual Air Conditioning System) Inspect the servo motor operation. Connect the positive (+) lead from the battery to terminal 5 and negative (-) lead to terminal 1, and then check that the arm turns to the "FRESH" side smoothly. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 5, and then check that the arm turns to the "RECIRCULATION" side smoothly. if the operation is not as specified, replace the air inlet servo motor.

INSTALLATION

1. INSTALL AIR INLET CONTROL SERVO MOTOR (See «INSTALLATION»(ref-265087-S13090314802007092000000) )
2. INSTALL BLOWER ASSEMBLY Install the blower (see «INSTALLATION»(ref-265087-S13090314802007092000000) ).

Scheme 265

1. REMOVE AIR CONDITIONING UNIT Remove the air conditioning radiator (see «REMOVAL»(ref-265087-S23722011562007092000000) ).
2. REMOVE AIR OUTLET CONTROL SERVO MOTOR (See «DISASSEMBLY»(ref-265087-S17123996852007092000000) )

Scheme 266

Scheme 267

1. INSPECT AIR OUTLET CONTROL SERVO MOTOR Inspect the servo motor operation. Connect the positive (+) lead from the battery to terminal 4 and negative (-) lead to terminal 5, and then check that the lever turns to the "FACE" position smoothly. Connect the positive (+) lead from the battery to terminal 5 and negative (-) lead to terminal 4, and then check that the lever turns to the "DEF" position smoothly. If the operation is not as specified, replace the air outlet control servo motor.

1. INSTALL AIR OUTLET CONTROL SERVO MOTOR (See «INSTALLATION»(ref-265087-S13942694552007092000000) )
2. INSTALL AIR CONDITIONING UNIT Install the air conditioning radiator (see «INSTALLATION»(ref-265087-S13942694552007092000000) ).

Scheme 268

1. REMOVE AIR CONDITIONING UNIT Remove the air conditioning radiator (see «REMOVAL»(ref-265087-S23722011562007092000000) ).
2. REMOVE AIR MIX CONTROL SERVO MOTOR (See «DISASSEMBLY»(ref-265087-S17123996852007092000000) )

Scheme 269

Scheme 270

1. INSPECT AIR MIX CONTROL SERVO MOTOR Inspect the servo motor operation. Connect the positive (+) lead from the battery to terminal 4 and negative (-) lead to terminal 5, and then check that the lever turns to the "MAX HOT" position smoothly. Connect the positive (+) lead from the battery to terminal 5 and negative (-) lead to terminal 4, and then check that the lever turns to the "MAX COOL" position smoothly. If the operation is not as specified, replace the air mix control servo motor.

1. INSTALL AIR MIX CONTROL SERVO MOTOR (See «INSTALLATION»(ref-265087-S13942694552007092000000) )
2. INSTALL AIR CONDITIONING UNIT Install the air conditioning radiator (see «INSTALLATION»(ref-265087-S13942694552007092000000) ).

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Scheme 274

1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See «REPLACEMENT»(ref-265087-S42514689952007092000000) )
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
3. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE Remove the bolt and disconnect the cooler refrigerant suction hose from the cooler compressor. Remove the O-ring from the cooler refrigerant suction hose. NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.
4. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE Remove the bolt and disconnect the cooler refrigerant discharge hose from the cooler compressor. Remove the O-ring from the cooler refrigerant discharge hose. NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.
5. REMOVE NO. 1 ENGINE UNDER COVER
6. REMOVE FAN AND GENERATOR V BELT (See «ON-VEHICLE INSPECTION»(ref-265058-S27382850712007092000000) )
7. REMOVE COOLER COMPRESSOR ASSEMBLY Disconnect the connector. w/o Stud Bolt: Remove the 4 bolts and cooler compressor. w/Stud Bolt: Remove the 3 bolts, nut and cooler compressor.

Scheme 275

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Scheme 277

1. ADJUST COMPRESSOR OIL When replacing the compressor and magnetic clutch with a new one, gradually discharge the refrigerant gas from the service valve, and drain the following amount of oil from the new compressor and magnetic clutch before installation. Standard: (Oil capacity inside the new compressor and magnetic clutch: 130 + 15 cc (4.6 + 0.51 fl.oz.) ) -(Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed from the new compressor when replacing) NOTE: When checking the compressor oil level, observe the precautions on the cooler removal/installation. If a new compressor and magnetic clutch is installed without removing some oil remaining in the pipes of the vehicle, the oil amount will be too large. This prevents heat exchange in the refrigerant cycle and causes refrigerant failure. If the volume of oil remaining in the removed compressor and magnetic clutch is too small, check for oil leakage. Be sure to use ND-OIL 8 or equivalent for compressor oil.
2. INSTALL COOLER COMPRESSOR ASSEMBLY w/o Stud Bolt: Install the cooler compressor with the 4 bolts. Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf) NOTE: Tighten the bolts in the order shown in the illustration to install the cooler compressor. w/Stud Bolt: Install the cooler compressor with the 3 bolts and nut. Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf) NOTE: Tighten the bolts in the order shown in the illustration to install the cooler compressor. Connect the connector.
3. INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE Remove the attached vinyl tape from the hose. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor. Compressor oil: ND-OIL 8 or equivalent Install the O-ring on the cooler refrigerant discharge hose. Install the cooler refrigerant discharge hose on the cooler compressor with the bolt. Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf)
4. INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE Remove the attached vinyl tape from the hose. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor. Compressor oil: ND-OIL 8 or equivalent Install the O-ring on the cooler refrigerant suction hose. Install the cooler refrigerant suction hose on the cooler compressor with the bolt. Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf)
5. INSTALL FAN AND GENERATOR V BELT (See «REMOVAL»(ref-265058-S40920015262007092000000) )
6. INSTALL NO. 1 ENGINE UNDER COVER
7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
8. CHARGE REFRIGERANT (See «REPLACEMENT»(ref-265087-S42514689952007092000000) )
9. WARM UP ENGINE (See «REPLACEMENT»(ref-265087-S42514689952007092000000) )
10. CHECK FOR LEAKAGE OF REFRIGERANT (See «REPLACEMENT»(ref-265087-S42514689952007092000000) )

Scheme 278

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Scheme 281

1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See «REPLACEMENT»(ref-265087-S42514689952007092000000) )
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
3. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE Remove the bolt and disconnect the cooler refrigerant suction hose from the cooler compressor. Remove the O-ring from the cooler refrigerant suction hose. NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.
4. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE Remove the bolt and disconnect the cooler refrigerant discharge hose from the cooler compressor. Remove the O-ring from the cooler refrigerant discharge hose. NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.
5. REMOVE FAN AND GENERATOR V BELT (See «VALVE CLEARANCE»(ref-265058-S22397489382007092000000) )
6. REMOVE COOLER COMPRESSOR ASSEMBLY Disconnect the connector. Remove the 4 bolts and cooler compressor.

Scheme 282

Scheme 283

Scheme 284

1. INSTALL COOLER COMPRESSOR ASSEMBLY Install the cooler compressor with the 4 bolts. Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf) NOTE: Tighten the bolts in the order shown in the illustration to install the cooler compressor. Connect the connector.
2. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE Remove the attached vinyl tape from the hose. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor. Compressor oil: ND-OIL 8 or equivalent Install the O-ring to the cooler refrigerant discharge hose. Connect the cooler refrigerant discharge hose to the cooler compressor with the bolt. Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf)
3. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE Remove the attached vinyl tape from the hose. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor. Compressor oil: ND-OIL 8 or equivalent Install the O-ring to the cooler refrigerant suction hose. Connect the cooler refrigerant suction hose to the cooler compressor with the bolt. Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf)
4. INSTALL FAN AND GENERATOR V BELT (See «VALVE CLEARANCE»(ref-265058-S22397489382007092000000) )
5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
6. CHARGE REFRIGERANT (See «REPLACEMENT»(ref-265087-S42514689952007092000000) )
7. WARM UP ENGINE (See «REPLACEMENT»(ref-265087-S42514689952007092000000) )
8. CHECK FOR LEAKAGE OF REFRIGERANT (See «REPLACEMENT»(ref-265087-S42514689952007092000000) )

Scheme 285

Scheme 286

1. INSTALL ROOM TEMPERATURE SENSOR Attach the claws to install the sensor. Connect the connector. Connect the duct.
2. INSTALL LOWER INSTRUMENT PANEL Install the lower instrument panel (see «INSTALLATION»(ref-265064-S25394910402007092000000) ).

Scheme 287

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT BUMPER COVER Remove the front bumper cover (see «REMOVAL»(ref-265092-S20173643722007092000000) ).
3. REMOVE AMBIENT TEMPERATURE SENSOR Using a screwdriver, pull out the sensor, then disconnect the connector. HINT: Tape the screwdriver tip before use.

Scheme 288

1. INSPECT AMBIENT TEMPERATURE SENSOR Measure the resistance of the sensor. Standard resistance TERMINALS RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 1 - 2 10°C (50°F) 3.00 to 3.73 k 1 - 2 15°C (59°F) 2.45 to 2.88 k 1 - 2 20°C (68°F) 1.95 to 2.30 k 1 - 2 25°C (77°F) 1.60 to 1.80 k 1 - 2 30°C (86°F) 1.28 to 1.47 k 1 - 2 35°C (95°F) 1.00 to 1.22 k 1 - 2 40°C (104°F) 0.80 to 1.00 k 1 - 2 45°C (113°F) 0.65 to 0.85 k 1 - 2 50°C (122°F) 0.50 to 0.70 k 1 - 2 55°C (131°F) 0.44 to 0.60 k 1 - 2 60°C (140°F) 0.36 to 0.50 k NOTE: Touching the sensor even slightly may change the resistance value. Hold the connector of the sensor. When measuring the resistance, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (Scheme 288) If the result is not as specified, replace the ambient temperature sensor.

1. INSTALL AMBIENT TEMPERATURE SENSOR Connect the connector, and then push in the sensor.
2. INSTALL FRONT BUMPER COVER Install the front bumper cover (see «FRONT BUMPER»(ref-265092-S26759249342007092000000) ).
3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
4. CHECK SRS WARNING LIGHT Check the SRS warning light (see «DIAGNOSIS SYSTEM»(ref-281539-S07592235132008031700000) ).

1. REMOVE AIR CONDITIONING UNIT Remove the air conditioning radiator (see «REMOVAL»(ref-265087-S23722011562007092000000) ).
2. REMOVE EVAPORATOR TEMPERATURE SENSOR (See «DISASSEMBLY»(ref-265087-S17123996852007092000000) )

Scheme 289

1. INSPECT EVAPORATOR TEMPERATURE SENSOR Measure the resistance of the sensor. Standard resistance TERMINALS RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 1 - 2 -10°C (14°F) 7.30 to 9.10 k 1 - 2 -5°C (23°F) 5.65 to 6.95 k 1 - 2 0°C (32°F) 4.40 to 5.35 k 1 - 2 5°C (41°F) 3.40 to 4.15 k 1 - 2 10°C (50°F) 2.70 to 3.25 k 1 - 2 15°C (59°F) 2.14 to 2.58 k 1 - 2 20°C (68°F) 1.71 to 2.05 k 1 - 2 25°C (77°F) 1.38 to 1.64 k 1 - 2 30°C (86°F) 1.11 to 1.32 k NOTE: Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. When measuring, the sensor temperature must be almost the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (Scheme 289) If the result is not as specified, replace the sensor.

1. INSTALL EVAPORATOR TEMPERATURE SENSOR (See «DISASSEMBLY»(ref-265087-S17123996852007092000000) )
2. INSTALL AIR CONDITIONING UNIT Install the air conditioning unit (see «INSTALLATION»(ref-265087-S13942694552007092000000) ).

Scheme 290

Scheme 291

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE SOLAR SENSOR Using a screwdriver, pull out the solar sensor, then disconnect the connector. HINT: Tape the screwdriver tip before use.

Scheme 292

1. INSPECT SOLAR SENSOR Using an ohmmeter, connect the positive lead to terminal 2 and the negative lead to terminal 1, then measure the resistance between the terminals. Standard resistance TERMINALS RESISTANCE SPECIFICATION Tester Connection Connection Specified Condition 1 - 2 Sensor subject to electric light Except infinity ohms 1 - 2 Sensor covered with a cloth Infinity ohms (No continuity) NOTE: The connection procedure for using a digital tester such as a TOYOTA electrical tester is shown above. When using an analog tester, connect the positive (+) lead to terminal 1 and the negative (-) lead to terminal 2 of the A/C solar sensor. HINT: As the inspection light is moved away from the sensor, the voltage increases. Use an incandescent lamp for inspection. Bring it within 30 cm (11.8 in.) of the A/C solar sensor. If the result is not as specified, replace the solar sensor.

1. INSTALL SOLAR SENSOR Connect the connector, and then push in the solar sensor.
2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
3. CHECK SRS WARNING LIGHT Check the SRS warning light (see «DIAGNOSIS SYSTEM»(ref-281539-S07592235132008031700000) ).

Scheme 293

Scheme 294

1. CHECK PRESSURE SENSOR Check the wire harness. Disconnect the connector of the pressure sensor. Measure the resistance of the wire harness side connector. Standard resistance TERMINALS RESISTANCE SPECIFICATION Tester Connection Specified Condition 1 - Body ground Below 1 Turn the ignition switch ON. Measure the voltage of the wire harness side connector. Standard voltage TERMINALS VOLTAGE SPECIFICATION Tester Connection Specified Condition 1 - 3 4.7 to 5.3 V If the result is not as specified, replace the pressure sensor. Check the pressure sensor. Set the manifold gauge. Connect the connector to the pressure sensor. Warm up the engine. Switch the A/C ON. Measure the voltage. Standard voltage TERMINALS VOLTAGE SPECIFICATION Tester Connection Refrigerant Pressure Specified Condition for Automatic Air Conditioner: E37-9 (PRE) - E37-13 (SG-2) 0.176 to 3.025 MPa (1.8 to 30.9 kgf/cm 2 ) 0.76 to 4.74 V for Manual Air Conditioner: E36-12 (PRE) - E36-10 (SG-2) 0.176 to 3.025 MPa (1.8 to 30.9 kgf/cm 2 ) 0.76 to 4.74 V If the result is not as specified, replace the pressure sensor.

Scheme 295

1. INSPECT RELAY (Marking: HTR) Measure the resistance of the HTR relay. Standard resistance TERMINALS RESISTANCE SPECIFICATION Tester Connection Specified Condition 3 - 4 Below 1 3 - 5 10 k or higher 3 - 5 Below 1 (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay.

Scheme 296

Scheme 297

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL CENTER (See REMOVAL under «UPPER INSTRUMENT PANEL»(ref-265064-S25734899672007092000000) )
3. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL CENTER (See REMOVAL under «UPPER INSTRUMENT PANEL»(ref-265064-S25734899672007092000000) )
4. REMOVE RADIO RECEIVER (See REMOVAL under «UPPER INSTRUMENT PANEL»(ref-265064-S25734899672007092000000) )
5. REMOVE AIR CONDITIONING CONTROL ASSEMBLY Remove the 2 screws. Using a screwdriver, detach the 3 clips. HINT: Tape the screwdriver tip before use. Connect the connectors and remove the air conditioning control.

Scheme 298

1. INSTALL AIR CONDITIONING CONTROL ASSEMBLY Connect the connectors. Attach the 3 clips to install the air conditioning control. Install the 2 screws.
2. INSTALL RADIO RECEIVER (See «INSTALLATION»(ref-265064-S40675824202007092000000) )
3. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL CENTER (See «INSTALLATION»(ref-265064-S40675824202007092000000) )
4. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL CENTER (See «INSTALLATION»(ref-265064-S40675824202007092000000) )
5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
6. CHECK SRS WARNING LIGHT Check the SRS warning light (see «DIAGNOSIS SYSTEM»(ref-281539-S07592235132008031700000) ).

Scheme 299

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Scheme 303

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL CENTER (See REMOVAL under «UPPER INSTRUMENT PANEL»(ref-265064-S25734899672007092000000) )
3. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL CENTER (See REMOVAL under «UPPER INSTRUMENT PANEL»(ref-265064-S25734899672007092000000) )
4. REMOVE RADIO RECEIVER ASSEMBLY (See REMOVAL under «UPPER INSTRUMENT PANEL»(ref-265064-S25734899672007092000000) )
5. REMOVE AIR CONDITIONING CONTROL ASSEMBLY Remove the 2 screws. Using a screwdriver, detach the 3 clips. HINT: Tape the screwdriver tip before use. Disconnect the connectors and remove the air conditioning control.
6. REMOVE AIR MIX CONTROL SWITCH Detach the 2 claws and remove the air mix control switch.
7. REMOVE BLOWER CONTROL SWITCH Detach the 2 claws and remove the blower control switch.
8. REMOVE AIR VENT MODE CONTROL SWITCH Detach the 2 claws and remove the mode control switch.

Scheme 304

1. INSTALL AIR VENT MODE CONTROL SWITCH Attach the 2 claws to install the mode control switch.
2. INSTALL BLOWER CONTROL SWITCH Attach the 2 claws to install the blower control switch.
3. INSTALL AIR MIX CONTROL SWITCH Attach the 2 claws to install the air mix control switch.
4. INSTALL AIR CONDITIONING CONTROL ASSEMBLY Connect the connectors. Attach the 3 clips to install the air conditioning control. Install the 2 screws.
5. INSTALL RADIO RECEIVER ASSEMBLY (w/Radio Receiver) (See «INSTALLATION»(ref-265064-S40675824202007092000000) )
6. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL CENTER (See «INSTALLATION»(ref-265064-S40675824202007092000000) )
7. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL CENTER (See «INSTALLATION»(ref-265064-S40675824202007092000000) )
8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
9. CHECK SRS WARNING LIGHT Check the SRS warning light (see «DIAGNOSIS SYSTEM»(ref-281539-S07592235132008031700000) ).

Scheme 305

Scheme 306

1. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY Detach the clamp. Disconnect the connector. Remove the screw and A/C amplifier.

Scheme 307

1. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY Install the A/C amplifier with the screw. Connect the connector. Attach the clamp.