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Home >> Toyota >> 2009 >> RAV4 Base, 2.5 F, AWD >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> Air Conditioning >> Air Conditioning Unit >> Disassembly

Air Conditioning Unit: Disassembly

  1. REMOVE NO. 3 HEATER TO REGISTER DUCT 
    1. Detach the 6 claws and remove the heater to register duct.
      Fig 1: Identifying Heater To Register Duct Claws
      G05585356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE AIR DUCT 
    1. Detach the 2 claws and remove the air duct.
      Fig 2: Identifying Air Duct Claws
      G06003906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE AIR OUTLET CONTROL SERVO MOTOR 
    1. Remove the 3 screws.
    2. Detach the evaporator case from the blower case.
      Fig 3: Identifying Evaporator Case To Blower Case Screws
      G05585358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 3 screws and disconnect the connector.
    4. Remove the air outlet control servo motor.
      Fig 4: Identifying Air Outlet Control Servo Motor Screws
      G05585359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE AIR MIX CONTROL SERVO MOTOR 
    1. Remove the 3 screws and disconnect the connector.
    2. Remove the air mix control servo motor.
      Fig 5: Identifying Air Mix Control Servo Motor Screws
      G05585360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
      Fig 6: Identifying Evaporator Case To Blower Case Screws
      G05585358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Detach the 3 claws and remove the cable.
      Fig 7: Removing Mode Control Cable Assembly
      G05585362Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REPAIR AIRMIX DAMPER CONTROL CABLE SUB-ASSEMBLY (for Manual Air Conditioning System) 
    1. Detach the 3 claws and remove the cable.
      Fig 8: Removing/Installing Airmix Damper Control Cable
      G05585363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY 
    1. Detach the screw and remove the clamp.
    2. Remove the heater radiator unit.
      Fig 9: Identifying Heater Radiator Unit With Clamp And Screw
      G05585364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
      Fig 10: Identifying Cooler Expansion Valve Bolts
      G05585365Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY 
    1. Remove the 4 screws.
    2. Detach the 2 claws and remove the cover.
      Fig 11: Identifying Screw And Claws On Cover
      G05585366Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Detach the cooler thermistor clamp.
    4. Remove the cooler thermistor and cooler evaporator from the case.
      Fig 12: Identifying Cooler Thermistor Clamp
      G05585367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE EVAPORATOR TEMPERATURE SENSOR 
    1. Disconnect the cooler thermistor clamp from the cooler evaporator.
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