Air Conditioning System (Service Information): Overview Toyota RAV4 IV

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1. INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET This method uses a manifold gauge set to locate problem areas. Read the manifold gauge pressure when these conditions are established. Test conditions: Temperature at the air inlet is 30 to 35°C (86 to 95°F). Engine is running at 1, 500 rpm. All doors are fully open. Blower speed control switch is at HI. A/C switch is ON. Gauge readings (Reference). Normally functioning refrigeration system Gauge reading Pressure side Refrigerant volume Low 0.15 to 0.25 MPa (1.5 to 2.5 kgf/cm2) High 1.37 to 1.57 MPa (14 to 16 kgf/cm2) The A/C system periodically changes between normal and improper function due to moisture in the refrigerant system. Symptoms Probable Cause Diagnosis Corrective Actions During operation, pressure on low pressure side cycles between normal and vacuum Moisture in refrigeration system freezes at expansion valve orifice, causing temporary stop of cycle. However, when melted, normal state is restored. - Drier is overly saturated - Moisture in refrigeration system freezes at expansion valve orifice and blocks refrigerant circulation 1. Replace cooler drier 2. Remove moisture from cycle by repeatedly evacuating air 3. Supply appropriate volume of new refrigerant The A/C system does not function effectively due to insufficient cooling. Symptoms Probable Cause Diagnosis Corrective Actions - Pressure low on both low and high pressure sides - Cooling performance insufficient Gas leakage from refrigeration system - Insufficient refrigerant - Refrigerant leakage 1. Check for gas leakage and repair if necessary 2. Supply appropriate volume of new refrigerant 3. If indicated pressure value close to 0 when connected to gauge, create vacuum after inspecting and repairing the location of leakage The A/C system does not function effectively due to poor circulation of the refrigerant. Symptoms Probable Cause Diagnosis Corrective Actions - Pressure low on both low and high pressure sides - Frost exists on piping from condenser to A/C unit Refrigerant flow obstructed by dirt in condenser Condenser clogged Replace condenser The A/C system does not function intermittently because the refrigerant does not circulate. Symptoms Probable Cause Diagnosis Corrective Actions - Vacuum indicated on low pressure side, and extremely low pressure indicated on high pressure side - Frost or condensation seen on piping on both sides of condenser or expansion valve - Refrigerant flow obstructed by moisture or dirt in refrigeration system - Refrigerant flow obstructed by gas leakage from expansion valve Refrigerant does not circulate 1. Check expansion valve refrigerant 2. Clean expansion valve by blowing air 3. Replace condenser 4. Evacuate air and charge appropriate volume of new refrigerant 5. For gas leakage from expansion valve, replace expansion valve The A/C system does not function effectively due to overcharged refrigerant or insufficient cooling of the condenser. Symptoms Probable Cause Diagnosis Corrective Actions Pressure extremely high on both low and high-pressure sides - Excessive refrigerant - Cooling performance of condenser insufficient - Condenser is dirty - Condenser fan motor is malfunctioning - Excessive refrigerant 1. Clean condenser 2. Check condenser fan motor operation 3. If 1 and 2 normal, check the amount of refrigerant and supply appropriate volume of refrigerant The A/C system does not function due to air in the refrigeration system. WARNING: The low-pressure piping may be very hot and cause serious burns. Symptoms Probable Cause Diagnosis Corrective Actions - Pressure extremely high on both low and high-pressure sides - Low-pressure piping is too hot to touch Air in refrigeration system - Air in refrigeration system - Vacuum purging insufficient 1. Check if compressor oil is dirty or insufficient 2. Evacuate air and charge new refrigerant The A/C system does not function effectively due to an expansion valve malfunction. Symptoms Probable Cause Diagnosis Corrective Actions - Pressure extremely high on both low and high-pressure sides - Frost or condensation on piping on low-pressure side Problem with expansion valve - Excessive refrigerant in low pressure piping - Expansion valve too wide open Replace expansion valve The A/C system does not function due to a defective compressor. Symptoms Probable Cause Diagnosis Corrective Actions - Pressure extremely high on both low and high-pressure sides - Pressure extremely low on high pressure side Internal leakage in compressor - Compression failure - Leakage from damaged valve or broken sliding parts Repair or replace compressor

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1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM Start up the engine. Turn the A/C switch ON. Operate the cooler compressor with an engine speed of approximately 1, 000 rpm for 5 to 6 minutes to circulate the refrigerant and collect the compressor oil remaining in each component into the cooler compressor. Stop the engine. Recover the refrigerant from the A/C system using a refrigerant recovery unit.
2. CHARGE REFRIGERANT Perform vacuum purging using a vacuum pump. Charge refrigerant HFC-134a (R134a). SST: 09985-20010 09985-02010 09985-02050 09985-02060 09985-02070 09985-02080 09985-02090 09985-02110 09985-02130 09985-02140 09985-02150 Standard for 2AR-FE: 450 +-30 g (15.9 +-1.1 oz.) for 2GR-FE: 490 +-30 g (17.3 +-1.1 oz.) NOTE: Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat. Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.
3. WARM UP ENGINE Warm up the engine at less than 1, 850 rpm for 2 minutes or more after charging the refrigerant. NOTE: Be sure to warm up the compressor when turning the A/C switch ON after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.
4. INSPECT FOR REFRIGERANT LEAK After recharging with refrigerant gas, inspect for refrigerant leak gas using a halogen leak detector. Perform the operation under these conditions: Stop the engine. Secure good ventilation (the gas leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas). Repeat the test 2 or 3 times. Make sure that some refrigerant remains in the refrigeration system. When compressor is off: approximately 392 to 588 kPa (4 to 6 kgf/cm 2 , 57 to 85 psi) Using a gas leak detector, inspect for refrigerant leak from the refrigerant lines. If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test. Disconnect the connector and leave the pressure switch on for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test.

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1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM See step 1
2. DRAIN ENGINE COOLANT for 2AR-FE: Drain engine coolant.Refer to «REPLACEMENT - Step 2»(ref-493447-S27817726442012081000000). for 2GR-FE: Drain engine coolant.Refer to «REPLACEMENT - Step 2»(ref-493469-S00017665692012081000000).
3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
4. REMOVE TUBE SUB-ASSEMBLY Remove the bolt. Remove plate, as shown in the illustration. Disconnect the suction tube and liquid tube. NOTE: Do not use a screwdriver or similar tool to disconnect the tube. Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them. Remove the 2 O-rings from the suction tube and liquid tube.
5. DISCONNECT INLET HEATER WATER HOSE Using pliers, grip the claws of the clip and slide the clip. Disconnect the heater water inlet hose.
6. DISCONNECT OUTLET HEATER WATER HOSE HINT: Disconnection of the heater water outlet hose is the same as for the heater water inlet hose.
7. REMOVE STEERING COLUMN ASSEMBLY Remove the steering column.Refer to «REMOVAL»(/toyota/rav4/iv-2012-2015/remont/steering-column/#steering-column-service-information__removal) .
8. REMOVE UPPER INSTRUMENT PANEL Remove the upper instrument panel.Refer to «REMOVAL»(/toyota/rav4/iv-2012-2015/remont/gauges-instrument-panels/#instrument-panel-service-information) .
9. REMOVE LOWER INSTRUMENT PANEL Remove the lower instrument panel.Refer to «REMOVAL»(/toyota/rav4/iv-2012-2015/remont/gauges-instrument-panels/#instrument-panel-service-information) .
10. REMOVE DEFROSTER NOZZLE ASSEMBLY Detach the 3 claws and remove the defroster nozzle assembly.
11. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY Fold the floor carpet back. Disconnect the clamp and disconnect the wire harness. Remove the bolt, nut, screw, and instrument panel brace.
12. REMOVE AIR DUCT REAR Disconnect the 2 clamps and disconnect the wire harness. Detach the 3 claws and remove the air duct rear.
13. REMOVE AIR DUCT Detach the 2 claws and remove the air duct.
14. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY Detach the 2 clamps. Disconnect the connector. Remove the screw and amplifier.
15. REMOVE DRAIN COOLER HOSE Remove the drain hose.
16. REMOVE INSTRUMENT PANEL REINFORCEMENT Disconnect the 12 clamps. Remove the 4 bolts and disconnect the ground wire. Remove the 3 bolts. Remove the 6 bolts and instrument panel reinforcement.
17. REMOVE AIR CONDITIONER UNIT ASSEMBLY Remove the bolt, nut and A/C unit.

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1. REMOVE NO. 3 HEATER TO REGISTER DUCT Detach the 6 claws and remove the heater to register duct.
2. REMOVE AIR DUCT Detach the 2 claws and remove the air duct.
3. REMOVE QUICK HEATER ASSEMBLY (w/ PTC Heater) See step 2
4. REMOVE AIR OUTLET CONTROL SERVO MOTOR (for Automatic Air Conditioning System) Remove the 3 screws. Detach the evaporator case from the blower case. Remove the 3 screws and disconnect the connector. Remove the air outlet control servo motor.
5. REMOVE AIR MIX CONTROL SERVO MOTOR (for Automatic Air Conditioning System) Remove the 3 screws and disconnect the connector. Remove the air mix control servo motor.
6. REMOVE MODE CONTROL CABLE ASSEMBLY (for Manual Air Conditioning System) Remove the 3 screws. Detach the evaporator case from the blower case. Detach the 3 claws and remove the cable.
7. REPAIR AIRMIX DAMPER CONTROL CABLE SUB-ASSEMBLY (for Manual Air Conditioning System) Detach the 3 claws and remove the cable.
8. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY Detach the screw and remove the clamp. Remove the heater radiator unit.
9. REMOVE COOLER EXPANSION VALVE Using a 4 mm hexagon wrench, remove the 2 hexagon bolts. Remove the cooler expansion valve and 2 O-rings from the cooler evaporator.
10. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY Remove the 4 screws. Detach the 2 claws and remove the cover. Detach the cooler thermistor clamp. Remove the cooler thermistor and cooler evaporator from the case.
11. REMOVE EVAPORATOR TEMPERATURE SENSOR Disconnect the cooler thermistor clamp from the cooler evaporator.

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1. INSTALL EVAPORATOR TEMPERATURE SENSOR NOTE: If reusing the evaporator, do not insert the sensor to a location where the sensor was previously inserted. Insert the sensor within range C shown in the illustration. Install the evaporator temperature sensor as shown in the illustration.
2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY Install the cooler thermistor and cooler evaporator on the case. Attach the temperature sensor clamp. Attach the 2 claws to install the cover. Install the 4 screws.
3. INSTALL COOLER EXPANSION VALVE Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the hose joint. Compressor oil ND-OIL 8 or equivalent Install the 2 O-rings to the cooler evaporator. Install the cooler expansion valve. Using a 4 mm hexagon wrench, install the A/C tube with the 2 hexagon bolts. Torque: 3.5 N*m (35 kgf*cm, 30 in.*lbf)
4. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY Install the heater radiator with the clamp and screw.
5. INSTALL AIRMIX DAMPER CONTROL CABLE SUB-ASSEMBLY (for Manual Air Conditioning System) Attach the 3 claws to install the cable.
6. INSTALL MODE CONTROL CABLE ASSEMBLY (for Manual Air Conditioning System) Attach the 3 claws to install the cable. Attach the evaporator case to the blower case. Install the cable with the 3 screws.
7. INSTALL AIR MIX CONTROL SERVO MOTOR (for Automatic Air Conditioning System) Install the air mix control servo motor with the 3 screws and connect the connector.
8. INSTALL AIR OUTLET CONTROL SERVO MOTOR (for Automatic Air Conditioning System) Install the air outlet control servo motor with the 3 screws and connect the connector. Attach the evaporator case to the blower case. Install the 3 screws.
9. INSTALL QUICK HEATER ASSEMBLY (w/ PTC Heater) See step 1
10. INSTALL AIR DUCT Attach the 2 claws and install the air duct.
11. INSTALL NO. 3 HEATER TO REGISTER DUCT Attach the 6 claws and install the heater to register duct.

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1. INSTALL AIR CONDITIONER UNIT ASSEMBLY Install the A/C unit with the bolt and nut. Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf)
2. INSTALL INSTRUMENT PANEL REINFORCEMENT Install the instrument panel reinforcement with the 6 bolts. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) Install the 3 bolts. Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf) Install the 4 bolts and connect the ground wire. Attach the 12 clamps.
3. INSTALL DRAIN COOLER HOSE Install the drain hose.
4. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY Install the A/C amplifier with the screw. Connect the connector. Attach the 2 clamps to the amplifier.
5. INSTALL AIR DUCT Attach the 2 claws and install the air duct.
6. INSTALL REAR AIR DUCT Attach the 3 claws and install the air duct rear. Attach the 2 clamps and install the wire harness.
7. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY Install the instrument panel brace with the bolt, nut and screw. Install the clamp and connect the wire harness. Reposition the floor carpet.
8. INSTALL DEFROSTER NOZZLE ASSEMBLY Attach the 3 claws and install the defroster nozzle assembly lower.
9. INSTALL LOWER INSTRUMENT PANEL Install the lower instrument panel.Refer to «INSTALLATION»(/toyota/rav4/iv-2012-2015/remont/gauges-instrument-panels/#instrument-panel-service-information) .
10. INSTALL UPPER INSTRUMENT PANEL Install the upper instrument panel.Refer to «INSTALLATION»(/toyota/rav4/iv-2012-2015/remont/gauges-instrument-panels/#instrument-panel-service-information) .
11. INSTALL STEERING COLUMN ASSEMBLY Install the steering column.Refer to «INSTALLATION - Step 1»(/toyota/rav4/iv-2012-2015/remont/steering-column/#steering-column-service-information) .
12. CONNECT HEATER WATER OUTLET HOSE Connect the water hose and attach the clip.
13. CONNECT HEATER WATER INLET HOSE HINT: Use the same procedures described for the water outlet hose.
14. CONNECT TUBE SUB-ASSEMBLY Remove the attached vinyl tape from the pipe. Sufficiently apply compressor oil to new 2 O-rings and the fitting surface of the suction tube and liquid tube. Compressor oil ND-OIL 8 or equivalent Install the 2 O-rings on the suction tube and liquid tube. Connect the suction tube and liquid tube. HINT: After the connection, check that the claw of the piping clamp is engaged. Install the plate with the bolt. Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf)
15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
16. CHECK SRS WARNING LIGHT Check the SRS warning light.Refer to «DIAGNOSIS SYSTEM»(ref-493514-S21857056482012081000000).
17. REPLACE ENGINE COOLANT for 2GR-FE: Refer to the following procedures.Refer to «REPLACEMENT»(ref-493469-S41134300492012081000000). for 2AR-FE: Refer to the following procedures.Refer to «REPLACEMENT»(ref-493447-S33681470782012081000000).
18. CHARGE REFRIGERANT See step 2
19. WARM UP ENGINE See step 3
20. INSPECT FOR COOLANT LEAK
21. INSPECT FOR REFRIGERANT LEAK See step 4

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See also:
• REMOVAL
• REMOVAL
• INSTALLATION - Step 1