Air Conditioning. Air Conditioning Unit Installation

Heater & Air Conditioning System. Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

Air Conditioning. Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

Air Conditioning Unit -- Installation

1. INSTALL AIR CONDITIONING UNIT ASSEMBLY

Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

Install the air conditioning 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

Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Air Conditioning.Air Conditioning System (For Automatic Air Conditioning System).Air Conditioning Unit Installation

Install the air conditioning amplifier with the screw.

Connect the connector.

Attach the 2 clamps to the amplifier.

5. INSTALL AIR DUCT

Attach the 2 claws to install the air duct.

6. INSTALL REAR AIR DUCT

Attach the 3 claws to install the air duct rear.

Attach the 2 clamps to 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 to install the defroster nozzle assembly lower.

9. INSTALL LOWER INSTRUMENT PANEL

Install the lower instrument panel (RAV4_ACA30 RM000001RHG00HX.html).

10. INSTALL UPPER INSTRUMENT PANEL

Install the upper instrument panel (RAV4_ACA30 RM000001RHA00KX.html).

11. INSTALL STEERING COLUMN ASSEMBLY

Install the steering column (RAV4_ACA30 RM000000UCX01XX_01_0015.html).

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 (RAV4_ACA30 RM000000YE2063X_04_0005.html).

17. ADD ENGINE COOLANT

For 1AZ-FE, refer to the following procedures (RAV4_ACA30 RM000001YMM00SX_01_0003.html).
For 2GR-FE, refer to the following procedures (RAV4_ACA30 RM000001YMM00TX_01_0003.html).
For 2AZ-FE, refer to the following procedures (RAV4_ACA30 RM000001YMM00UX_01_0003.html).
For 3ZR-FAE, refer to the following procedures (RAV4_ACA30 RM000001YMM00YX_01_0011.html).

18. CHARGE REFRIGERANT

Perform vacuum purging using a vacuum pump.

Charge refrigerant HFC-134a (R134a).
Standard:
430 +-30 g (15.2 +-1.1 oz.)
SST
09985-20010(09985-02130,09985-02150,09985-02090,09985-02110,09985-02010,09985-02050,09985-02060,09985-02070)

NOTICE:
1. Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.
2. 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.

19. WARM UP ENGINE

Warm up the engine at less than 1,850 rpm for 2 minutes or more after charging the refrigerant.
NOTICE:
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.

20. CHECK FOR ENGINE COOLANT LEAKS

For 1AZ-FE: (RAV4_ACA30 RM000001YMM00SX_01_0006.html)
For 2GR-FE: (RAV4_ACA30 RM000001YMM00UX_01_0004.html)
For 2AZ-FE: (RAV4_ACA30 RM000001YMM00TX_01_0008.html)
For 3ZR-FAE: (RAV4_ACA30 RM000001YMM00YX_01_0014.html)

21. CHECK FOR LEAKAGE OF REFRIGERANT

After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.

Perform the operation under these conditions:
1. Stop the engine.
2. Secure good ventilation (the gas leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).
3. Repeat the test 2 or 3 times.
4. Make sure that some refrigerant remains in the refrigeration system. When compressor is off: approximately 392 to 588 kPa (4 to 6 kgf/cm², 57 to 85 psi)

Using a gas leak detector, check the refrigerant line for leakage.

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.