Toyota RAV4 Service Manual: Reassembly
- Install evaporator temperature sensor
Notice:
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.
- Install no. 1 Cooler evaporator subassembly
- 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.
- 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)
- Install heater radiator unit sub-assembly
- Install the heater radiator with the clamp and screw.
- Install airmix damper control cable subassembly (for manual air conditioning system)
- Attach the 3 claws to install the cable.
- 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.
- Install air mix control servo motor
- Install the air mix control servo motor with the 3 screws and connect the connector.
- Install air outlet control servo motor
- 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.
- Install air duct
- Attach the 2 claws and install the air duct.
- Install no. 3 Heater to register duct
- Attach the 6 claws and install the heater to register duct.
Disassembly
Remove no. 3 Heater to register duct
Detach the 6 claws and remove the heater to
register duct.
Remove air duct
Detach the 2 claws and remove the air duct.
Remove ...
Installation
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)
Install instrument panel reinforcement
Install th ...
Other materials:
Precaution
If any of following conditions are met,
keep engine idling with a/c on (engine
speed at less than 2000 rpm) for at least 1
minute:
Refrigerant gas has been refilled or a/c parts have
been replaced.
A long time has elapsed since the engine was
stopped.
Notice:
If the engine s ...
Headlight assembly
Components
Removal
Hint:
Use the same procedures for the rh and lh sides.
The procedures listed below are for the lh side.
Disconnect cable from negative battery
terminal
Remove front fender liner lh (see page et-4)
Remove front fender liner rh (see page et-4)
Remove ra ...
Disassembly
Hint:
When removing the ornament plate and emblem, heat the
radiator grille, ornament plate and emblem using a heat light.
Standard heating temperature
Notice:
Do not heat the emblem base and emblem excessively.
Remove hood to radiator grille seal
Remove the double-side tape.
Deta ...
