Toyota RAV4 (XA40) 2013-2018 Service Manual: Reassembly

1. 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.

1. Install the evaporator temperature sensor as shown in the illustration.

2. Install no. 1 Cooler evaporator subassembly

1. Install the cooler thermistor and cooler evaporator on the case.
2. Attach the temperature sensor clamp.

3. Attach the 2 claws to install the cover.
4. Install the 4 screws.

3. Install cooler expansion valve

1. Sufficiently apply compressor oil to 2 new o-rings and the fitting surface of the hose joint.

Compressor oil: nd-oil 8 or equivalent

2. Install the 2 o-rings to the cooler evaporator.
3. Install the cooler expansion valve.
4. 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

1. Install the heater radiator with the clamp and screw.

5. Install airmix damper control cable subassembly (for manual air conditioning system)

1. Attach the 3 claws to install the cable.

6. Install mode control cable assembly (for manual air conditioning system)

1. Attach the 3 claws to install the cable.

2. Attach the evaporator case to the blower case.
3. Install the cable with the 3 screws.

7. Install air mix control servo motor

1. Install the air mix control servo motor with the 3 screws and connect the connector.

8. Install air outlet control servo motor

1. Install the air outlet control servo motor with the 3 screws and connect the connector.

2. Attach the evaporator case to the blower case.
3. Install the 3 screws.

9. Install air duct

1. Attach the 2 claws and install the air duct.

10. Install no. 3 Heater to register duct

1. Attach the 6 claws and install the heater to register duct.