Toyota RAV4 Service Manual: Disassembly

1. Remove no. 3 Heater to register duct

1. Detach the 6 claws and remove the heater to register duct.

2. Remove air duct

1. Detach the 2 claws and remove the air duct.

3. Remove air outlet control servo motor

1. Remove the 3 screws.
2. Detach the evaporator case from the blower case.

4. Remove air mix control servo motor

1. Remove the 3 screws and disconnect the connector.
2. Remove the air mix control servo motor.

5. Remove mode control cable assembly (for manual air conditioning system)

1. Remove the 3 screws.
2. Detach the evaporator case from the blower case.

3. Detach the 3 claws and remove the cable.

6. Repair airmix damper control cable subassembly (for manual air conditioning system)

1. Detach the 3 claws and remove the cable.

7. Remove heater radiator unit sub-assembly

1. Detach the screw and remove the clamp.
2. Remove the heater radiator unit.

8. Remove cooler expansion valve

1. Using a 4 mm hexagon wrench, remove the 2 hexagon bolts.
2. Remove the cooler expansion valve and 2 o-rings from the cooler evaporator.

9. Remove no. 1 Cooler evaporator subassembly

1. Remove the 4 screws.
2. Detach the 2 claws and remove the cover.

3. Detach the cooler thermistor clamp.
4. Remove the cooler thermistor and cooler evaporator from the case.

10. Remove evaporator temperature sensor

1. Disconnect the cooler thermistor clamp from the cooler evaporator.