Toyota - RAV4 - Parts Catalogue - 1967 - 2020

2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 2008 HVAC Air Conditioning - RAV4 AIR CONDITIONING SYSTEM (FOR AUTOMATIC AIR CONDITIONING SYSTEM) PRECAUTION 1. 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. NOTE: If the engine speed exceeds 2,000 rpm, the A/C compressor may be damaged. 2. DO NOT HANDLE REFRIGERANT IN ENCLOSED AREAS OR NEAR OPEN FLAMES 3. ALWAYS WEAR EYE PROTECTION Fig. 1: Precaution For Handle Refrigerant In Enclosed Area Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN YOUR EYES OR ON YOUR SKIN Microsoft Tuesday, August 18, 2009 3:54:02 3:53:52 PM Page 1 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 If liquid refrigerant gets in your eyes or on your skin: a. Wash the area with lots of cold water. CAUTION: Do not rub your eyes or skin. b. Apply clean petroleum jelly to the skin. c. Go immediately to a physician or hospital for professional treatment. Fig. 2: Precaution For Liquid Refrigerant Eyes On Skin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. NEVER HEAT CONTAINER OR EXPOSE IT TO OPEN FLAME 6. BE CAREFUL NOT TO DROP CONTAINER OR SUBJECT IT TO PHYSICAL SHOCKS 7. DO NOT OPERATE COMPRESSOR WITH INSUFFICIENT REFRIGERANT IN REFRIGERANT SYSTEM If there is not enough refrigerant in the refrigerant system, oil lubrication will be insufficient and compressor burnout may occur. Necessary care should be taken to avoid this. Fig. 3: Identifying Correct And Incorrect Connection Of Valves Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Microsoft Tuesday, August 18, 2009 3:53:52 PM Page 2 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 8. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATING Open and close only the low pressure valve. Opening and closing the high pressure valve could cause the charging cylinder to rupture. 9. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT If the refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy and engine overheating. 10. DO NOT OPERATE ENGINE AND COMPRESSOR WITHOUT REFRIGERANT NOTE: This may damage the inside of the compressor. PARTS LOCATION Fig. 4: Identifying Air Conditioning System Components Location (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Fig. 5: Identifying Air Conditioning System Components Location (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Microsoft Tuesday, August 18, 2009 3:53:52 PM Page 3 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 6: Identifying Air Conditioning System Components Location (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SYSTEM DIAGRAM Fig. 7: Air Conditioning System Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Communication table COMMUNICATION CHART Sender Air conditioning amplifier Air conditioning amplifier Receiver Signal A/C compressor control signal Idle up request signal External variable control solenoid current signal ECM Cooling fan motor driving request signal Ambient temperature signal Front panel indication signal AUTO indication signal Air conditioning control A/C indication signal MODE indication signal assembly REC indication signal FRS indication signal Communication Line CAN LIN Microsoft Tuesday, August 18, 2009 3:53:52 PM Page 4 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Combination meter assembly Air conditioning amplifier ECM Air conditioning amplifier Air conditioning control assembly Air conditioning amplifier RDEF indication signal Blower level indication signal Set temperature indication signal Vehicle speed signal Ambient temperature signal Engine revolution speed signal Engine coolant temperature signal A/C control cut signal Variable control prohibition signal AUTO switch signal OFF switch signal A/C switch signal DEF switch signal MODE switch signal RDEF switch signal Blower switch signal (FAN+, FAN-) Set temperature switch signal (UP, DOWN) CAN CAN LIN SYSTEM DESCRIPTION 1. GENERAL a. The air conditioning system has the following features:  In accordance with the temperature set using the temperature control switch, the air conditioning amplifier determines the outlet temperature based on the input signals from various sensors. In addition, corrections are made in accordance with the signals from the water temperature sensor to control the outlet air temperature.  Controls the blower motor in accordance with the airflow volume determined by the air conditioning amplifier based on the input signals from various sensors.  Automatically changes the outlets in accordance with the outlet mode ratio that is determined by the air conditioning amplifier based on the input signals from various sensors.  Based on the signals from the ambient temperature sensor, this system calculates the outside temperature and indicates it in the multi-information display in the combination meter assembly.  The left/right independent temperature control and neural network control make air conditioner control available to suit the persons in the driver seat and in the passenger seat.  Turns the rear defogger and outside rear mirror heaters on for 15 minutes when the rear defogger switch is pressed. Turns them off if the switch is pressed while they are operating.  Checks the sensors in accordance with the operation of the air conditioner switches. Microsoft Tuesday, August 18, 2009 3:53:52 PM Page 5 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 The air conditioning amplifier has the function of controlling the indicator lighting. 2. MODE POSITION AND DAMPER OPERATION  Fig. 8: Identifying Mode Position And Damper Operation Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DAMPER POSITION OPERATION CHART Control Damper Air Inlet Control Damper Air Mix Control Driver and Damper (Left/Right Front Independent Passenger Control) Side Mode Control Film Damper Driver and Front Passenger Side Damper Operation Position FRESH A Brings in fresh air. RECIRC B Recirculates internal air. MAX COOL to MAX Varies mixture ratio of fresh air and HOT (TEMP. recirculation air in order to regulate C, D, E SETTING 18 to 32°C temperature continuously from (65 to 85°F)) HOT to COOL. I, J, L, P, Air blows out of center registers and FACE U side registers. Air mainly blows out of center I, Q, M, BI-LEVEL registers, side registers, and R, T footwell register ducts. Air mainly blows out of front and rear footwell register ducts. H, K, N, FOOT In addition, air blows out slightly O, S from front and side defrosters, and side registers. Air mainly blows out of front and side defrosters to defrost G, K, N, FOOT/DEF windshield. Air also blows out from O, T front and rear footwell register ducts, and side registers. Air blows out of front and side F, K, N, DEF defrosters and side registers to O, U defrost windshield. Control Position 3. AIR OUTLET AND AIRFLOW VOLUME Microsoft Tuesday, August 18, 2009 3:53:52 PM Page 6 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 9: Identifying Air Outlet And Airflow Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. The circle size (O) indicates the proportion of the flow volume. Fig. 10: Air Outlet Position Symbol Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HOW TO PROCEED WITH TROUBLESHOOTING HINT:   Use these procedures to troubleshoot the air conditioning system. *: Use Techstream. 1. VEHICLE BROUGHT TO WORKSHOP 2. CUSTOMER PROBLEM ANALYSIS AND SYMPTOM CHECK 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. 4. CHECK CAN COMMUNICATION SYSTEM* a. Use Techstream to check if the CAN communication system is functioning. Microsoft Tuesday, August 18, 2009 3:53:52 PM Page 7 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Result RESULT REFERENCE Result Proceed to CAN DTC is not output A CAN DTC is output B B: Go to CAN COMMUNICATION SYSTEM A: Go to next step 5. CHECK DTC OR CHECK SENSOR CHECK CODE THROUGH PANEL DIAGNOSIS* a. Check DTCs or sensor check codes. 1. Write down the DTCs or sensor check codes. b. Clear the DTCs or sensor check codes. c. Check whether the DTCs or sensor check codes recur. 1. Reproduce the problem symptoms in accordance with the DTCs or sensor check codes that were written down, and check whether the DTCs or sensor check codes recur. HINT: Refer to the DTC chart when any DTCs or sensor check codes are output. Result RESULT REFERENCE Result Proceed to DTC or sensor check code is not output A DTC or sensor check code is output B B: Go to step 8 A: Go to next step 6. REFER TO PROBLEM SYMPTOMS TABLE Result RESULT REFERENCE Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B B: Go to step 8 Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 8 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 A: Go to next step 7. OVERALL ANALYSIS AND TROUBLESHOOTING* a. DATA LIST / ACTIVE TEST (see DATA LIST / ACTIVE TEST ) b. Panel diagnosis (indicator check) (see CHECK MODE PROCEDURE ) c. Panel diagnosis (sensor check) (see CHECK MODE PROCEDURE ) d. Panel diagnosis (actuator check) (see CHECK MODE PROCEDURE ) e. Terminals of ECU (see TERMINALS OF ECU ) 8. ADJUST, REPAIR OR REPLACE 9. CONFIRMATION TEST NEXT: END CUSTOMIZE PARAMETERS HINT: The following items can be customized. NOTE:    When the customer requests a change in a function, first make sure that the function can be customized. Be sure to make a note of the current settings before customizing. When troubleshooting a function, first make sure that the function is set to the default setting. Air conditioning system AIR CONDITIONING SYSTEM - TROUBLESHOOTING CHART Display Default Contents Setting Set Temperature To control with shifted temperature against +2 C / +1 C / NORMAL Shift display temperature NORMAL / -1 C / -2 C In case of turning A/C ON when you desire to make compartment cool down quickly, this is Air Inlet Mode AUTO MANUAL/AUTO function to change mode automatically to RECIRCULATION mode Compressor / Air Function to turn A/C ON automatically linked Inlet DEF LINK NORMAL / LINK with FRONT DEF button when A/C is OFF Operation Function to set evaporator control to AUTOMATIC position (AUTO) to save power, or Evaporator AUTO MANUAL/AUTO to coldest position (MANUAL) to dehumidify air Control and to prevent windows from fogging up Foot / DEF Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 9 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Automatic Blow up Function Ambient Temperature Shift ON Normal Function to change blower level automatically when defroster is ON OFF/ON To control with shifted ambient temperature against display ambient temperature. +3 C / +2 C / +1 C / Normal / -1 C / -2 C / 3C PROBLEM SYMPTOMS TABLE HINT:   Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. Inspect the fuses and relays related to this system before inspecting the suspected areas below. Air conditioning system PROBLEM SYMPTOMS CHART Symptom Suspected area 1. LIN communication line 2. Air conditioning No functions of A/C panel operate control assembly 3. Air conditioning amplifier 1. ECU-IG2 fuse 2. Air conditioning control assembly No functions of A/C system 3. Air conditioning operate amplifier 4. Wire harness or connector 1. HTR fuse 2. Blower motor circuit 3. Air conditioning Airflow Control: No blower amplifier control (Blower motor does not 4. Air conditioning operate) control assembly 5. Wire harness or connector 1. Blower motor circuit Airflow Control: No blower 2. Air conditioning control (Blower motor does not amplifier change speed) 3. Air conditioning See AIR CONDITIONING CONTROL PANEL DOES NOT OPERATE TERMINALS OF ECU AIR CONDITIONING CONTROL PANEL DOES NOT OPERATE TERMINALS OF ECU BLOWER MOTOR CIRCUIT TERMINALS OF ECU AIR CONDITIONING CONTROL PANEL DOES NOT OPERATE BLOWER MOTOR CIRCUIT TERMINALS OF ECU AIR CONDITIONING CONTROL Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 10 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 control assembly PANEL DOES NOT OPERATE 1. Refrigerant volume 2. Refrigerant pressure 3. Air conditioning DTC B1423/23 PRESSURE SENSOR pressure sensor CIRCUIT 4. Compressor and pulley DTC B1451/51 COMPRESSOR (for 2AZ-FE) SOLENOID CIRCUIT 5. Compressor and DTC B1451/51 COMPRESSOR magnetic clutch (for 2GRSOLENOID CIRCUIT FE) 6. Compressor circuit (for COMPRESSOR CIRCUIT 2GR-FE) 7. Driver side air mix DTC B1446/46 AIR MIX DAMPER damper control servo CONTROL SERVO MOTOR CIRCUIT motor circuit (DRIVER SIDE) 8. Passenger side air mix DTC B1441/41 AIR MIX DAMPER damper control servo CONTROL SERVO MOTOR CIRCUIT (PASSENGER SIDE) Temperature Control: No cool air motor circuit 9. Evaporator temperature DTC B1413/13 EVAPORATOR comes out sensor circuit TEMPERATURE SENSOR CIRCUIT 10. Room temperature DTC B1411/11 ROOM sensor circuit TEMPERATURE SENSOR CIRCUIT 11. Ambient temperature DTC B1412/12 AMBIENT sensor circuit TEMPERATURE SENSOR CIRCUIT 12. Expansion valve 13: Air conditioning TERMINALS OF ECU amplifier 14. Air conditioning AIR CONDITIONING CONTROL PANEL DOES NOT OPERATE control assembly 15. ECM (for 2AZ-FE) SFI SYSTEM 16. ECM (for 2GR-FE) SFI SYSTEM 17. LIN communication line 18. CAN communication CAN COMMUNICATION SYSTEM system 1. Driver side air mix DTC B1446/46 AIR MIX DAMPER damper control servo CONTROL SERVO MOTOR CIRCUIT motor circuit (DRIVER SIDE) 2. Passenger side air mix DTC B1441/41 AIR MIX DAMPER CONTROL SERVO MOTOR CIRCUIT damper control servo (PASSENGER SIDE) motor circuit 3. Air conditioning harness 4. Room temperature DTC B1411/11 ROOM Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 11 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Temperature Control: No warm air comes out Temperature Control: Output air is warmer or cooler than set temperature or response is slow Temperature Control: No temperature control (Only Max. cool or Max. warm) sensor circuit 5. Air conditioning amplifier 6. Air conditioning control assembly 7. ECM (for 2AZ-FE) 8. ECM (for 2GR-FE) 9. LIN communication line 10. CAN communication system 1. Driver side solar sensor circuit 2. Passenger side solar sensor circuit 3. Room temperature sensor circuit 4. Air inlet damper control servo motor circuit 5. Heater radiator 6. Expansion valve 7. Air conditioning amplifier 8. Air conditioning control assembly 9. ECM (for 2AZ-FE) 10. ECM (for 2GR-FE) 11. LIN communication line 12. CAN communication system 1. Driver side solar sensor circuit 2. Passenger side solar sensor circuit 3. Air conditioning amplifier 4. Air conditioning control assembly 5. LIN communication line TEMPERATURE SENSOR CIRCUIT 1. Air conditioning AIR CONDITIONING CONTROL TERMINALS OF ECU AIR CONDITIONING CONTROL PANEL DOES NOT OPERATE SFI SYSTEM SFI SYSTEM CAN COMMUNICATION SYSTEM DTC B1424/24 SOLAR SENSOR CIRCUIT (DRIVER SIDE) DTC B1421/21 SOLAR SENSOR CIRCUIT (PASSENGER SIDE) DTC B1411/11 ROOM TEMPERATURE SENSOR CIRCUIT DTC B1442/42 AIR INLET DAMPER CONTROL SERVO MOTOR CIRCUIT TERMINALS OF ECU AIR CONDITIONING CONTROL PANEL DOES NOT OPERATE SFI SYSTEM SFI SYSTEM CAN COMMUNICATION SYSTEM DTC B1424/24 SOLAR SENSOR CIRCUIT (DRIVER SIDE) DTC B1421/21 SOLAR SENSOR CIRCUIT (PASSENGER SIDE) TERMINALS OF ECU AIR CONDITIONING CONTROL PANEL DOES NOT OPERATE - Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 12 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 control assembly 2. Air inlet damper control servo motor circuit No air inlet control 3. Evaporator temperature sensor circuit 4. Air conditioning amplifier 1. Compressor circuit (for Engine idle up does not occur, or 2GR-FE) 2. ECM (for 2AZ-FE) is continuos. 3. ECM (for 2GR-FE) Diagnostic trouble codes are not 1. Air conditioning amplifier recorded. Set mode is cleared when ignition switch turned to 2. Back-up power source LOCK circuit PANEL DOES NOT OPERATE DTC B1442/42 AIR INLET DAMPER CONTROL SERVO MOTOR CIRCUIT DTC B1413/13 EVAPORATOR TEMPERATURE SENSOR CIRCUIT TERMINALS OF ECU COMPRESSOR CIRCUIT SFI SYSTEM SFI SYSTEM TERMINALS OF ECU BACK-UP POWER SOURCE CIRCUIT TERMINALS OF ECU 1. CHECK AIR CONDITIONING AMPLIFIER Fig. 11: Identifying ECU And E36 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Measure the voltage and resistance of the connectors. HINT: Check from the rear of the connector while it is connected to the air conditioning amplifier. TERMINAL DESCRIPTION Symbols Wiring Terminal Condition (Terminal No.) Color Description B (E37-21) Power source (BackR - W-B Always GND (E37-14) up) Specified Condition 10 to 14 V Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 13 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 SOL+ (E37-2) A/C compressor GR - W-B GND (E37-14) operation signal Engine idling Blower switch LO A/C switch ON BLW (E37-23) Blower motor control Ignition switch ON R - W-B GND (E37-14) signal Blower switch LO PRE (E37-9) SG-2 (E37-13) L-G PRE (E37-9) SG-2 (E37-13) L-G PRE (E37-9) SG-2 (E37-13) L-G TSD (E37-33) S5-4 (E37-31) L - LG TSP (E37-32) S5-4 (E37-31) P - LG TR (E37-29) SG-1 (E37-34) GR - V SG-1 (E37-34) - V - Body Body ground ground W-B GND (E37-14) Body Body ground ground IG+ (E37-1) Y - W-B GND (E37-14) S5-3 (E37-10) B - W-B GND (E37-14) Air conditioning Refrigerant pressure: Normal pressure sensor signal Refrigerant pressure: Air conditioning Abnormal (less than 0.196 pressure sensor signal MPa [2.0 kgf/cm2 , 28 psi]) Refrigerant pressure: Air conditioning Abnormal (more than 3.14 pressure sensor signal MPa [32 kgf/cm2 , 455 psi]) Ignition switch ON Driver side solar Solar sensor subject to sensor signal electric light Ignition switch ON Passenger side solar Solar sensor subject to sensor signal electric light Ignition switch ON Room temperature Vehicle interior temperature: sensor signal 25°C (77°F) Ground for room Always temperature sensor 4.74 V or higher 0.8 to 4.3 V 0.8 to 4.3 V 1.8 to 2.2 V Below 1 ohms Power source (IG) Ignition switch ON 10 to 14 V Power supply for pressure sensor Ignition switch ON 4.5 to 5.5 V CANL(E37-12) Lo-level CAN bus W - W-B - GND (E37-14) line Ignition switch ON B - W-B Below 0.76 V Always Ignition switch ON RDFG (E37-38) 0.76 to 4.74 V Ground for main power supply CANH (E37-11) Hi-level CAN bus V - W-B - GND (E37-14) line SG-2 (E37-13) - G - Body Body ground ground RDFG (E37-38) B - W-B - GND (E37-14) Pulse generation (see awaveform 1) Pulse generation (see bwaveform 2) Ground for pressure Always sensor Rear defogger switch Ignition switch ON Rear signal defogger switch OFF Rear defogger switch Ignition switch ON Rear Below 1 ohms Pulse generation (see cwaveform 3) Pulse generation (see dwaveform 4) Below 1 ohms 10 to 14 V Below 1 V Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 14 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 - GND (E37-14) LIN1 (E37-37) B - W-B GND (E37-14) BUB G (c1-2) Body ground BUS (c1-3) BUBG (d-2) BBUS (d-4) BUBG (c1-2) SGA (d-5) Body ground - signal LIN communication signal defogger switch ON Ground for BUS IC Always Ignition switch ON BUS IC control signal Ignition switch ON Power supply for BUS IC Ground for evaporator temperature sensor Evaporator temperature sensor signal Ignition switch ON Always Pulse generation Below 1 ohms Pulse generation 11 to 13 V Below 1 ohms Ignition switch ON 1.4 to 1.8 V Evaporator temperature: 15° C (59°F) Ignition switch ON AUTO Pulse generation LOCK (E37-8)* Compressor lock W-G switch ON A/C switch ON (see ewaveform - SG-2 (E37-13) sensor signal Magnetic clutch ON 5) MGC (E37-20)* Magnetic clutch relay Ignition switch ON Magnetic V - W-B 10 to 14 V - GND (E37-14) signal clutch OFF MGC (E37-20)* Magnetic clutch relay Ignition switch ON Magnetic V - W-B Below 1.5 V - GND (E37-14) signal clutch ON HINT: *: for 2GR-FE TEA (d-6) SGA (c1-5) - b. Using an oscilloscope, check waveform 1. A/C Compressor* operation signal A/C COMPRESSOR OPERATION SIGNAL REFERENCE Item Content Symbols (Terminal No.) SOL+ (E37-2) - GND (E37-14) Tool Setting 5 V/DIV., 500 µsec./DIV. Condition Engine idling, Blower switch LO, A/C switch ON HINT: *: Compressor and pulley for 2AZ-FE, Compressor and magnetic clutch for 2GR-FE. Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 15 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 12: Waveform Graph (Waveform 1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using an oscilloscope, check waveform 2. Blower motor control signal BLOWER MOTOR CONTROL SIGNAL REFERENCE Item Content Symbols (Terminal No.) BLW (E37-23) - GND (E37-14) Tool Setting 1 V/DIV., 500 µsec./DIV. Condition Ignition switch ON, Blower switch LO HINT: When the blower level is increased, the duty ratio changes accordingly. Fig. 13: Waveform Graph (Waveform 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using an oscilloscope, check waveform 3. CAN communication signal Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 16 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 CAN COMMUNICATION SIGNAL REFERENCE Item Content Symbols (Terminal No.) CANH (E37-11) - GND (E37-14) Tool Setting 1 V/DIV, 10 µsec/DIV. Condition Ignition switch ON HINT: The waveform varies depending on the CAN communication signal. Fig. 14: Waveform Graph (Waveform 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using an oscilloscope, check waveform 4. CAN communication signal CAN COMMUNICATION SIGNAL REFERENCE Item Content Symbols (Terminal No.) CANL (E37-12) - GND (E37-14) Tool Setting 1 V/DIV., 10 µsec/DIV. Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 17 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Condition Ignition switch ON HINT: The waveform varies depending on the CAN communication signal. Fig. 15: Waveform Graph (Waveform 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Using an oscilloscope, check waveform 5. Compressor lock sensor signal* COMPRESSOR LOCK SENSOR SIGNAL REFERENCE Item Content Symbols (Terminal LOCK (E37-8)* - SG-2 (E37-13) No.) Tool Setting 500 mV/DIV., 20 msec./DIV. Ignition switch ON, AUTO switch ON, A/C switch ON, Magnetic clutch Condition ON HINT: *: for 2GR-FE Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 18 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 16: Waveform Graph (Waveform 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. CHECK AIR CONDITIONING CONTROL Fig. 17: Identifying E23 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Measure the voltage and resistance of the connectors. TERMINAL DESCRIPTION Symbols (Terminal Wiring No.) Color IG+ (E23-2) - GND L - W-B (E23-7) GND (E23-7) W-B - Body Body ground ground LIN1 (E23-11) B - W-B GND (E23-7) +B (E23-1) - GND R - W-B (E23-7) ACC (E23-8) - GND GR - W-B (E23-7) Condition Specified Condition Ignition switch ON 10 to 14 V Ground for air conditioning control assembly Always Below 1 ohms LIN communication signal Ignition switch ON Pulse generation Power source (Back-up) Always 10 to 14 V ACC power supply Always Below 1 ohms Terminal Description Power source (IG) Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 19 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 DIAGNOSIS SYSTEM 1. DESCRIPTION a. Air conditioning system data and the Diagnostic Trouble Codes (DTCs) can be read through the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use Techstream to check for malfunctions and perform troubleshooting. 2. CHECK DLC3 The vehicle's ECM uses the ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Fig. 18: Identifying DLC3 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TERMINAL DESCRIPTION Symbols (Terminal No.) Terminal Description SIL (7) - SG (5) Bus "+" line CG (4) - Body ground Chassis ground SG (5) - Body ground Signal ground BAT (16) - Body ground Battery positive CANH (6) - CANL (14) CAN bus line CANH (6) - CG (4) Specified Condition Pulse generation Below 1 ohms Below 1 ohms 10 to 14 V Ignition switch LOCK(1) 54 to 69 ohms HIGH-level CAN bus line Ignition switch LOCK(1) 200 ohms or higher CANL (14) - CG (4) LOW-level CAN bus line CANH (6) -BAT (16) Condition During transmission Always Always Always Ignition switch LOCK(1) 200 ohms or higher HIGH-level CAN bus line Ignition switch LOCK(1) 6 kohms or higher Ignition switch LOCK(1) 6 kohms or higher (1) Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, other switches or doors. CANL (14) - BAT (16) LOW-level CAN bus line If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 20 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Connect the cable of Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction article. DTC CHECK / CLEAR 1. CHECK DTC a. Connect Techstream to the DLC3. b. Turn the ignition switch ON and turn Techstream ON. c. Read the DTC by following the prompts on the tester screen. HINT: Refer to Techstream operator's article for further details. 2. CLEAR DTC a. Connect Techstream to the DLC3. b. Turn the ignition switch ON and turn Techstream ON. c. Clear the DTC by following the prompts on the tester screen. HINT: Refer to Techstream operator's article for further details. CHECK MODE PROCEDURE 1. PANEL DIAGNOSIS (INDICATOR CHECK) a. Turn the ignition switch to LOCK. b. Turn the ignition switch ON while simultaneously pressing the A/C control AUTO switch and the REC/FRS switch. Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 21 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 19: Identifying A/C Control AUTO Switch And REC/FRS Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Check that all indicators and the display area are turned on and off 4 times in succession at 1 second intervals. Fig. 20: Identifying Indicator Blinking Pattern Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: After the indicator check is completed, the system automatically enters sensor check mode. d. Press the OFF switch to terminate the panel diagnosis. 2. PANEL DIAGNOSIS (SENSOR CHECK) a. Perform the indicator check. HINT: After the indicator check is completed, the system automatically enters sensor check mode. b. Press the REC/FRS switch to enter actuator check mode. c. After the actuator check is completed, press the AUTO switch to enter sensor check mode. Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 22 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 NOTE: The sensor check must be performed again after the actuator check is completed because sensor check mode, which starts automatically after the indicator check, cannot fully detect malfunctions. d. Check the sensor check results displayed on the set temperature display. RESULT REFERENCE Results Code Display Present malfunction Blinks Past malfunction Blinks HINT:     The illustration shows the display when code 21 is output. When 2 or more sensor check codes are detected, the codes are displayed in ascending numerical order. In cases with 2 or more codes, if they are difficult to read, press the DEF switch to activate the step operation and display them one by one. The codes are displayed in ascending numerical order as the DEF switch is pressed. Fig. 21: Identifying Display Temperature Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. When any sensor check codes are displayed, refer to the DTC chart (see DIAGNOSTIC TROUBLE CODE CHART ). f. Press the OFF switch to terminate the panel diagnosis. HINT: Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 23 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Pressing the REC/FRS switch returns the system to actuator check mode. 3. PANEL DIAGNOSIS (CLEAR SENSOR CHECK CODE) a. Inspect, and repair or replace the malfunctioning parts. b. Clear the sensor check codes. Fig. 22: Identifying DEF Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. While pressing the DEF switch during sensor check mode, press the Rr DEF switch. HINT: Sensor check codes can be cleared by removing the ECU-B2 fuse from the engine room No. 2 relay block for more than 60 seconds. c. Perform the sensor check and confirm that normal code 00 is displayed. 4. PANEL DIAGNOSIS (ACTUATOR CHECK) a. Start the engine and warm it up. b. Perform the indicator check. c. When the sensor check is started after the indicator check, press the REC/FRS switch to start the actuator check. HINT: Perform the actuator check with the engine running. Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 24 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 23: Identifying Actuator Blinking Pattern Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Check the temperature and blower levels by hand at each step while the actuator check proceeds from step 0 to 9 at 1 second intervals (continuous operation). Fig. 24: Identifying A/C Control AUTO Switch, REC/FRS Switch And DEF Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Each step number is displayed on the set temperature display. e. To display step numbers one by one manually, press the DEF switch to activate the step operation. The step number changes each time the DEF switch is pressed. HINT: Each step number blinks at 1 second intervals during the step operation.  The illustration shows the display when step number 5 is displayed. f. Press the OFF switch to terminate the panel diagnosis.  Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 25 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 HINT: Pressing the AUTO switch returns to sensor check mode. AIR FLOW VENT AND AIR INLET DAMPER CHART Step Blower Air Mix Air Flow Cool Air Air Inlet Damper Compressor No. Level Damper Vent By-pass 0% (MAX 0 0 FACE FRESH OFF COLD) 0% (MAX 1 1 FACE FRESH OFF COLD) 0% (MAX 2 17 FACE RECIRCULATION/FRESH ON COLD) 0% (MAX 3 17 FACE RECIRCULATION ON COLD) 4 17 50% BI-LEVEL RECIRCULATION ON 5 17 50% BI-LEVEL RECIRCULATION ON 6 17 50% FOOT FRESH ON 100% (MAX 7 17 FOOT FRESH ON HOT) 100% (MAX 8 17 FOOT/DEF FRESH ON HOT) 100% (MAX 9 31 DEF FRESH ON HOT) DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using Techstream to read the Data List allows the values or states of switches, sensors, actuators and other items to be read without removing any parts. This non-intrusive inspection can be very useful because intermittent conditions or signals may be discovered before parts or wiring is disturbed. Reading the Data List information early in troubleshooting is one way to save diagnostic time. a. Connect Techstream to the DLC3. b. Turn the ignition switch ON and turn Techstream ON. c. Read the Data List by following the prompts on the tester. Air conditioner: DATA LIST - AIR CONDITIONER Tester Display Measurement Normal Condition Diagnostic Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 26 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Item/Range Room temperature sensor / Room Temperature Actual room temperature is Min.: -6.5°C (20.3°F) Sensor displayed Max.:57.25°C (135.05°F) Ambient Temp Sensor Ambient temperature sensor / Min.: -23.3°C (- Actual ambient temperature is displayed 9.94°F) Max.: 65.95°C (150.71°F) Adjusted ambient Adjusted Ambient temperature / Min.: -30.8° C (-23.44°F) Temp Max.: 50.8°C (123.44°F) Note Open circuit: 6.5°C (20.3°F) Short circuit: 57.25°C (135.05°F) Open circuit: 23.3°C (-9.94° F) Short circuit: 65.95°C (150.71°F) - Open circuit: 29.7°C (-21.46° Evaporator temperature F) Evaporator Fin sensor / Min.:-29.7°C (Actual evaporator temperature is Short circuit: Thermistor displayed 21.46°F) 59.55°C Max.: 59.55°C (139.19°F) (139.19°F) Solar Sensor (D Driver side solar sensor / Driver side temperature side) Min.: 0, Max.: 255 increases as brightness increases Solar Sensor (P Passenger side solar Passenger side temperature side) sensor / Min.: 0, Max.: 255 increases as brightness increases Engine coolant Actual engine coolant Engine Coolant temperature / Min.: 1.3°C temperature is displayed after Temp (34.34°F) engine warmed up Max.:90.55°C (194.99°F) Driver side set Set Temperature (D temperature / Min.: 0°C Driver side actual set (32°F) side) temperature is displayed Max.: 30°C (54°F) Passenger side set Set Temperature (P temperature / Min.: 0°C Passenger side actual set side) temperature is displayed (32°F) Max.: 30°C (54°F) Increases in range between 0 and Blower Motor Blower motor speed level / 31 as blower motor speed Speed Level Min.: 0, Max.: 31 increases Regulator pressure sensor / Regulator Pressure Actual regulator pressure is Min.: -0.45668 MPaG Sensor displayed Max.: 3.29437 MPaG Regulator control current / Value changes between 0 A and Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 27 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Min.:0A Regulator Control Max.: 0.997 A Current Driver side air mix servo Air Mix Servo Targ motor target pulse / Min.: Pulse (D) 0, Max.: 255 Passenger side air mix Air Mix Servo Targ servo motor target pulse / Pulse (P) Min.: 0, Max.: 255 Air Outlet Servo Air outlet servo motor Pulse (D) target / Min.: 0, Max.: 255 Air Inlet Damper Air inlet damper target Targ Pulse pulse / Min.: 0, Max.: 255 Shift set temperature / +2 Shift Set C, +1 C, NORMAL, -1 C, Temperature -2 C Air inlet mode / AUTO, Air Inlet Mode MANUAL Compressor mode / Compressor Mode AUTO, MANUAL Compressor/DEF Compressor / DEF Mode / Mode LINK, NORMAL Evaporator Control / Evaporator Control AUTO, MANUAL Foot/DEF Auto Foot / DEF auto mode / Mode ON, OFF Foot / DEF automatic Foot/DEF Auto blow up function / ON, Blow Up OFF Ambient temperature Ambient shift / +3C, +2C, +1C, Temperature Shift Normal, -1C, -2C, -3C Number of Trouble Number of trouble codes / Codes Min.: 0, Max.: 255 0.997 A in accordance with compressor and magnetic clutch operation - Customized value displayed - Customized value displayed - Customized value displayed - Customized value displayed - Customized value displayed - Customized value displayed - Customized value displayed - Customized value displayed - Customized value displayed - Customized value displayed - Customized value displayed - Customized value displayed - Number of DTCs displayed - 2. PERFORM ACTIVE TEST HINT: Using Techstream to perform Active Tests allows the relay, actuator, and other items to operate without removing any parts. This non-intrusive functional inspection can be very useful because intermittent operation may be discovered before parts or wiring is disturbed. Performing Active Test early in troubleshooting is one way to save diagnostic time. Data List information can be display while performing Active Test. Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 28 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 a. Connect Techstream to the DLC3. b. Turn the ignition switch ON and turn Techstream ON. c. Perform the Active Test by following the prompts on the tester. Air conditioner: ACTIVE TEST - AIR CONDITIONER Tester Display Test Part Blower Motor Control Range Min.: 0, Max.: 31 Blower motor Magnetic Clutch Relay Magnetic clutch relay Defogger Relay (Rear) Air Mix Servo Tang Pulse (D) Air Mix Servo Tang Pulse (P) Air Outlet Servo Pulse (D) Air Inlet Damper Targ Pulse OFF, ON Defogger relay (Rear) OFF, ON Air mix servo motor pulse Min.: 0, Max.: (D side) 255 Air mix servo motor pulse (P Min.: 0, Max.: side) 255 Min.: 0, Max.: Air outlet servo motor pulse 255 Min.: 0, Max.: Air inlet damper target pulse 255 Diagnostic Note Operating sound can be heard - DIAGNOSTIC TROUBLE CODE CHART HINT: When the air conditioning system functions properly, DTC B1400/00 is output. Air conditioning system DIAGNOSTIC TROUBLE CODE CHART DTC No. Detection Item B1411/11 Room Temperature Sensor Circuit Trouble Area    B1412/12 Ambient Temperature Sensor Circuit  Room temperature sensor Wire harness between room temperature sensor and air conditioning amplifier Air conditioning amplifier Memory Memorized (8.5 min. or more) Ambient temperature Memorized (8.5 min. or more) sensor Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 29 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4     B1413/13 Evaporator Temperature Sensor Circuit    B1421/21 Solar Sensor Circuit (Passenger Side)    B1422/22 *1 Compressor Lock Sensor Circuit     Wire harness between ambient temperature sensor and combination meter assembly Combination meter assembly Air conditioning amplifier CAN communication line Memorized (8.5 min. or No. 1 cooler more) thermistor (Evaporator temperature sensor) Wire harness between No. 1 cooler thermistor (evaporator temperature sensor) and air conditioning amplifier Air conditioning amplifier Memorized (8.5 min. or Solar sensor more) Wire harness between solar sensor and air conditioning amplifier Air conditioning amplifier Compressor and magnetic clutch Compressor and magnetic clutch drive belt Compressor lock sensor Wire harness between compressor lock sensor and air conditioning amplifier Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 30 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4  B1423/23 Pressure Sensor Circuit    B1424/24 Solar Sensor Circuit (Driver Side)    B1441/41 Air Mix Damper Control Servo Motor Circuit (Passenger Side)    B1442/42 Air Inlet Damper Control Servo Motor Circuit    B1443/43 Air Outlet Damper Control Servo Motor Circuit    B1446/46 Air Mix Damper Control Servo Motor Circuit (Driver Side)    Air conditioning amplifier Air conditioning pressure sensor Wire harness between air conditioning pressure sensor and air conditioning amplifier Air conditioning amplifier Memorized (8.5 min. or Solar sensor more) Wire harness between solar sensor and air conditioning amplifier Air conditioning amplifier Air mix control servo Memorized (30 sec.) motor Air conditioning harness Air conditioning amplifier Air inlet control servo Memorized (30 sec.) motor Air conditioning harness Air conditioning amplifier Memorized (30 sec.) Air outlet control servo motor Air conditioning harness Air conditioning amplifier Air mix control servo Memorized (30 sec.) motor Air conditioning harness Air conditioning Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 31 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 amplifier B1451/51 Compressor Solenoid Circuit    B1497/97 BUS IC Communication Malfunction   B1499/99 Multiplex Communication Circuit     A/C Compressor*2 Wire harness between air conditioning amplifier and A/C compressor*2 Air conditioning amplifier Air conditioning harness Air conditioning amplifier Air conditioning amplifier ECM Combination meter assembly CAN communication line HINT: *1: DTC B1422/22 (Compressor Lock Sensor Circuit) is indicated only for a currently occurring malfunction for 2GR-FE. To confirm DTC B1422/22, perform the following steps: 1. With the ignition switch ON, enter the DTC check mode. 2. Press the R/F (Recirculation/Fresh) switch to enter actuator check mode, and set the operation to Step No. 3. 3. Press the AUTO switch to return to DTC check mode. 4. The DTC is displayed after approximately 3 seconds. *2: Compressor and pulley for 2AZ-FE, compressor and magnetic clutch for 2GR-FE DTC B1411/11 ROOM TEMPERATURE SENSOR CIRCUIT DESCRIPTION The room temperature sensor is installed in the instrument panel to detect the room temperature and control the heater and air conditioner AUTO mode. The resistance of the room temperature sensor changes in accordance with the room temperature. As the temperature decreases, the resistance increases. As the temperature increases, the resistance decreases. The air conditioning amplifier applies a voltage (5 V) to the room temperature sensor and reads voltage changes Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 32 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 as changes in the resistance of the room temperature sensor. DTC DETECTION CONDITION AND TROUBLE AREA REFERENCE DTC No. DTC Detection Condition Trouble Area  Open or short in room B1411/11 temperature sensor circuit   Room temperature sensor Harness and connector between room temperature sensor and air conditioning amplifier Air conditioning amplifier WIRING DIAGRAM Fig. 25: Identifying Room Temperature Sensor Circuit - Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE 1. READ VALUE OF TECHSTREAM a. Connect Techstream to the DLC3. b. Turn the ignition switch ON and turn Techstream ON. c. Select the item below in the Data List, and read the value displayed on Techstream. Air conditioning amplifier DATA LIST - AIR CONDITIONING AMPLIFIER Measurement Item / Display Item Normal Condition (Range) Room temperature sensor / Room Temperature Min.: -6.5°C (20.3°F) Sensor Max.: 57.25°C (135.05°F) Diagnostic Note Open circuit: -6.5°C Actual room (20.3°F) temperature is displayed Short circuit: 57.25X (135.05°F) OK: The display is as specified in the normal condition column. Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 33 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C: REPLACE AIR CONDITIONING AMPLIFIER ASSEMBLY A: Go to next step 2. INSPECT COOLER THERMISTOR (ROOM TEMPERATURE SENSOR) a. Remove the room temperature sensor. Fig. 26: Identifying Room Temperature Sensor Resistance Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance of the sensor. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 1 (ST+) - 2 (ST-) 10°C (50°F) 3.00 to 3.73 kohms 1 (ST+) - 2 (ST-) 15°C (59°F) 2.45 to 2.88 kohms 1 (ST+) - 2 (ST-) 20°C (68°F) 1.95 to 2.30 kohms 1 (ST+) - 2 (ST-) 25°C (77°F) 1.60 to 1.80 kohms 1 (ST+) - 2 (ST-) 30°C (86°F) 1.28 to 1.47 kohms 1 (ST+) - 2 (ST-) 35°C (95°F) 1.00 to 1.22 kohms 1 (ST+) - 2 (ST-) 40°C (104°F) 0.80 to 1.00 kohms 1 (ST+) - 2 (ST-) 45°C (113°F) 0.65 to 0.85 kohms 1 (ST+) - 2 (ST-) 50°C (122°F) 0.50 to 0.70 kohms Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 34 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 1 (ST+) - 2 (ST-) 1 (ST+) - 2 (ST-) 55°C (131°F) 0.44 to 0.60 kohms 60°C (140°F) 0.36 to 0.50 kohms NOTE:   Touching the sensor even slightly may change the resistance value. Be sure to hold the connector of the sensor. When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph ). NG: REPLACE COOLER THERMISTOR (ROOM TEMPERATURE SENSOR) OK: Go to next step 3. CHECK WIRE HARNESS (ROOM TEMPERATURE SENSOR - AIR CONDITIONING AMPLIFIER) a. Disconnect the E21 sensor connector. b. Disconnect the E37 amplifier connector. Fig. 27: Identifying E21 And E37 Amplifier Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Measure the resistance of the wire harness side connectors. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition E21-1 (ST+) - E37-29 (TR) Below 1 ohms E21-2 (ST-) - E37-34 (SG-1) Below 1 ohms Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 35 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 E21-1 (ST+) - Body ground 1 Mohms or higher E21-2 (ST-) - Body ground 1 Mohms or higher NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: REPLACE AIR CONDITIONING AMPLIFIER ASSEMBLY DTC B1412/12 AMBIENT TEMPERATURE SENSOR CIRCUIT DESCRIPTION The ambient temperature sensor is installed in the front part of the condenser to detect the ambient temperature and control the air conditioner. The sensor is connected to the combination meter and detects fluctuations in the ambient temperature. This data is used for controlling the room temperature. The sensor sends a signal to the air conditioning amplifier via the combination meter. The resistance of the ambient temperature sensor changes in accordance with the ambient temperature. As the temperature decreases, the resistance increases. As the temperature increases, the resistance decreases. The air conditioning amplifier applies a voltage (5 V) to the ambient temperature sensor and reads voltage changes as changes in the resistance of the ambient temperature sensor. The combination meter sends the read signal to the air conditioning amplifier via CAN communication. DTC DETECTION CONDITION AND TROUBLE AREA REFERENCE DTC No. DTC Detection Condition Trouble Area   Open or short in ambient B1412/12 temperature sensor circuit    Ambient temperature sensor Harness and connector between ambient temperature sensor and combination meter assembly Combination meter Air conditioning amplifier CAN communication line WIRING DIAGRAM Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 36 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 28: Identifying Ambient Temperature Sensor Circuit - Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE 1. READ VALUE OF TECHSTREAM a. Connect Techstream to the DLC3. b. Turn the ignition switch ON and turn Techstream ON. c. Select the item below in the Data List, and read the value displayed on Techstream. Air conditioning amplifier DATA LIST - AIR CONDITIONING AMPLIFIER Measurement Item / Display Item Normal Condition (Range) Ambient temperature sensor / Ambient Temp Min.: -23.3°C (-9.94°F) Sensor Max.: 65.95°C (150.71°F) Diagnostic Note Open circuit: -23.3°C Actual ambient (-9.94°F) temperature is displayed Short circuit: 65.95X (150.71°F) OK: The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 37 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 B: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C: REPLACE AIR CONDITIONING AMPLIFIER A: Go to next step 2. INSPECT AMBIENT TEMPERATURE SENSOR a. Remove the ambient temperature sensor. b. Measure the resistance of the sensor. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 1-2 10°C (50°F) 3.00 to 3.73 kohms 1-2 15°C (50°F) 2.45 to 2.88 kohms 1-2 20°C (68°F) 1.95 to 2.30 kohms 1-2 25°C (77°F) 1.60 to 1.80 kohms 1-2 30°C (86°F) 1.28 to 1.47 kohms 1-2 35°C (95°F) 1.00 to 1.22 kohms 1-2 40°C (104°F) 0.80 to 1.00 kohms 1-2 45°C (113°F) 0.65 to 0.85 kohms 1-2 50°C (122°F) 0.50 to 0.70 kohms 1-2 55°C (131°F) 0.44 to 0.60 kohms 1-2 60°C (140°F) 0.36 to 0.50 kohms NOTE:   Touching the sensor even slightly may change the resistance value. Be sure to hold the connector of the sensor. When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph ). Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 38 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 29: Ambient Temperature Sensor Resistance Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NG: REPLACE AMBIENT TEMPERATURE SENSOR OK: Go to next step 3. CHECK WIRE HARNESS (AMBIENT TEMPERATURE SENSOR - COMBINATION METER) a. Disconnect the A17 sensor connector. b. Disconnect the E19 meter connector. Fig. 30: Identifying A17 And E19 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Measure the resistance of the wire harness side connectors. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition A17-2 (OT+) - E19-23 (TEMP) Below 1 ohms Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 39 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 A17-1 (OT-) - E19-11 (TX1+) Below 1 ohms A17-2 (OT+) - Body ground 1 Mohms or higher A17-1 (OT-) - Body ground 1 Mohms or higher NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: REPLACE COMBINATION METER DTC B1413/13 EVAPORATOR TEMPERATURE SENSOR CIRCUIT DESCRIPTION The No. 1 cooler thermistor (evaporator temperature sensor) is installed on the evaporator in the air conditioning unit to detect the temperature of the cooled air that has passed through the evaporator and to control the air conditioner. It sends signals to the air conditioning amplifier. The signals change in accordance with the resistance of the No. 1 cooler thermistor (evaporator temperature sensor). As the temperature decreases, the resistance increases. As the temperature increases, the resistance decreases. The air conditioning amplifier applies a voltage (5 V) to the No. 1 cooler thermistor (evaporator temperature sensor) and reads voltage changes as changes in the resistance of the No. 1 cooler thermistor (evaporator temperature sensor). This sensor is used for frost prevention. DTC DETECTION CONDITION AND TROUBLE AREA REFERENCE DTC No. DTC Detection Condition Trouble Area  B1413/13 Open or short in evaporator temperature sensor circuit   No. 1 cooler thermistor (evaporator temperature sensor) Harness and connector between No. 1 cooler thermistor (evaporator temperature sensor) and air conditioning amplifier Air conditioning amplifier WIRING DIAGRAM Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 40 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 31: Identifying Evaporator Temperature Sensor Circuit - Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE 1. READ VALUE OF TECHSTREAM a. Connect Techstream to the DLC3. b. Turn the ignition switch ON and turn Techstream ON. c. Select the item below in the Data List, and read the value displayed on Techstream. Air conditioning amplifier DATA LIST - AIR CONDITIONING AMPLIFIER Measurement Item / Display Item Normal Condition (Range) Evaporator Fin Thermistor Diagnostic Note Open circuit: - 29.7° Evaporator temperature sensor / Actual evaporator C (-21.46°F) Min.:-29.7°C (-21.46°F) temperature is displayed Short circuit: 59.55° Max.: 59.55°C (139.19°F) C (139.19°F) OK: The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) P B: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C: REPLACE AIR CONDITIONING AMPLIFIER A: Go to next step 2. INSPECT NO. 1 COOLER THERMISTOR (EVAPORATOR TEMPERATURE SENSOR) a. Remove the No. 1 cooler thermistor. b. Measure the resistance of the thermistor. Standard resistance Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 41 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 1-2 -10°C (14°F) 7.30 to 9.10 kohms 1-2 -5°C (23°F) 5.65 to 6.95 kohms 1-2 0°C (32°F) 4.40 to 5.35 kohms 1-2 5°C (41°F) 3.40 to 4.15 kohms 1-2 10°C (50°F) 2.70 to 3.25 kohms 1-2 15°C (59°F) 2.14 to 2.58 kohms 1-2 20°C (68°F) 1.71 to 2.05 kohms 1-2 25°C (77°F) 1.38 to 1.64 kohms 1-2 30°C (86°F) 1.11 to 1.32 kohms NOTE:   Touching the thermistor even slightly may change the resistance value. Be sure to hold the connector of the thermistor. When measuring, the thermistor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph ). Fig. 32: Evaporator Temperature Sensor Resistance Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NG: REPLACE NO. 1 COOLER THERMISTOR OK: REPLACE AIR CONDITIONING HARNESS ASSEMBLY DTC B1421/21 SOLAR SENSOR CIRCUIT (PASSENGER SIDE) DESCRIPTION The solar sensor, which is installed on the upper side of the instrument panel, detects sunlight and controls the Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 42 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 air conditioning AUTO mode. The output voltage from the solar sensor varies in accordance with the amount of sunlight. When the sunlight increases, the output voltage increases. As the sunlight decreases, the output voltage decreases. The air conditioning amplifier detects changes in the output voltage from the solar sensor. DTC DETECTION CONDITION AND TROUBLE AREA REFERENCE DTC No. DTC Detection Condition Trouble Area  B1421/21 Open or short in passenger side solar sensor circuit   Solar sensor Harness and connector between solar sensor and air conditioning amplifier Air conditioning amplifier WIRING DIAGRAM Fig. 33: Identifying Solar Sensor Circuit - Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE 1. READ VALUE OF TECHSTREAM a. Connect Techstream to the DLC3. b. Turn the ignition switch ON and turn Techstream ON. c. Select the item below in the Data List, and read the value displayed on Techstream. Air conditioning amplifier DATA LIST - AIR CONDITIONING AMPLIFIER Measurement Item / Display Diagnostic Item Normal Condition (Range) Note Solar Sensor Passenger side solar sensor / Passenger side temperature increases (P side) Min.: 0, Max.: 255 as brightness increases OK: Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 43 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C: REPLACE AIR CONDITIONING AMPLIFIER A: Go to next step 2. INSPECT COOLER (SOLAR SENSOR) THERMISTOR a. Remove the solar sensor. b. Measure the resistance of the sensor. c. Connect the ohmmeter's positive (+) lead to terminal 1 and the negative (-) lead to terminal 2 of the solar sensor. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 1 (S5) - 2 (TSP) Sensor exposed to electric light Except infinity ohms 1 (S5) - 2 (TSP) Sensor covered with cloth infinity ohms (No continuity) NOTE: The connection procedure for using a digital tester such as an electrical tester is shown above. When using an analog tester, connect the positive (+) lead to terminal 2 and the negative (-) lead to terminal 1 of the solar sensor. HINT:   As the inspection light is moved away from the sensor, the voltage decreases. Use an incandescent light for the inspection. Position it about 30 cm (11.8 in.) from the solar sensor. Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 44 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 34: Identifying Solar Sensor TSP And S5 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NG: REPLACE COOLER (SOLAR SENSOR) THERMISTOR OK: Go to next step 3. CHECK WIRE HARNESS (SOLAR SENSOR - AIR CONDITIONING AMPLIFIER) a. Disconnect the F1 sensor connector. b. Disconnect the E37 amplifier connector. Fig. 35: Identifying F1 And E37 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Measure the resistance of the wire harness side connectors. Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 45 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition E37-32 (TSP) - F1 - 2 (TSP) Below 1 ohms E37-31 (S5-4) - F1-1 (S5) Below 1 ohms E37-32 (TSP) - Body ground 1 Mohms or higher E37-31 (S5-4) - Body ground 1 Mohms or higher NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: REPLACE AIR CONDITIONING AMPLIFIER DTC B1422/22 COMPRESSOR LOCK SENSOR CIRCUIT DESCRIPTION This sensor sends 1 pulse per engine revolution to the air conditioning amplifier. If the ratio of the compressor speed divided by the engine speed is smaller than a predetermined value, the air conditioning amplifier turns the compressor off, and the indicator blinks at approximately 1 second intervals. DTC DETECTION CONDITION AND TROUBLE AREA REFERENCE DTC No. DTC Detection Condition Trouble Area Open or short in compressor lock sensor circuit All conditions below are detected for 3 seconds or more: B1422/22    1. Engine speed: 450 rpm or more 2. Ratio between engine and compressor speed deviates 20% or more in comparison to normal operation   Compressor and magnetic clutch Compressor and magnetic clutch drive belt Compressor lock sensor Wire harness between compressor lock sensor and air conditioning amplifier Air conditioning amplifier WIRING DIAGRAM Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 46 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 36: Identifying Compressor Lock Sensor Circuit - Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE 1. CHECK AIR CONDITIONING AMPLIFIER (LOCK SIGNAL) a. Remove the air conditioning amplifier with its connectors still connected. b. Check the waveform of the amplifier connector. OK: Waveform is as shown in the illustration. ITEM CHART Item Content Tester Connection LOCK (E37-8) - SG-2 (E37-13) Tool Setting 500 mV/DIV, 20 msec./DIV. Ignition switch ON AUTO switch ON Condition A/C switch ON Magnetic clutch ON Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 47 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 37: Air Conditioning Amplifier Waveform Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C: REPLACE AIR CONDITIONING AMPLIFIER A: Go to next step 2. INSPECT COMPRESSOR LOCK SENSOR a. Disconnect the B47 compressor lock sensor connector. Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 48 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 38: Measuring Resistance Between Compressor Lock Sensor Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance of the sensor. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 1 (SSR+) - 2 (SSR-) 20°C (68°F) 65 to 125 ohms NG: REPLACE COMPRESSOR LOCK SENSOR OK: Go to next step 3. CHECK WIRE HARNESS (COMPRESSOR LOCK SENSOR - AIR CONDITIONING AMPLIFIER) a. Disconnect the B47 compressor lock sensor connector. b. Disconnect the E37 amplifier connector. Fig. 39: Identifying B47 And E37 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Measure the resistance of the wire harness side connectors. Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 49 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition B47-1 (SSR+) - E37-8 (LOCK) Below 1 ohms B47-2 (SSR-) - E37-13 (SG-2) Below 1 ohms B47-1 (SSR+) - E37-13 (SG-2) 10 kohms or higher E37-8 (LOCK) - Body ground 10 kohms or higher NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: REPLACE AIR CONDITIONING AMPLIFIER DTC B1423/23 PRESSURE SENSOR CIRCUIT DESCRIPTION This DTC is output when the refrigerant pressure is either extremely low (0.19 MPa [2.0 kgf/cm2 , 28 psi] or less) or extremely high (3.14 MPa [32.0 kgf/cm2 , 455 psi] or more). The air conditioning pressure sensor, which is installed on the pipe of the high pressure side, detects the refrigerant pressure and sends refrigerant pressure signals to the air conditioning amplifier. The air conditioning amplifier determines the pressure from the signals in accordance with the sensor characteristics, and controls the compressor accordingly. DTC DETECTION CONDITION AND TROUBLE AREA REFERENCE DTC No. DTC Detection Condition Trouble Area  Open or short in air conditioning B1423/23 pressure sensor circuit   Air conditioning pressure sensor Harness and connector between air conditioning pressure sensor and air conditioning amplifier Air conditioning amplifier WIRING DIAGRAM Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 50 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 40: Identifying Pressure Sensor Circuit - Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE 1. CHECK REFRIGERANT a. Check the sight glass of the cooler unit refrigerant liquid pipe. 1. Prepare the vehicle in accordance with the chart below. ITEM CHART Item Condition Engine Speed 1,500 rpm Vehicle Doors Fully open Temperature Setting MAX COLD Blower Speed HI A/C Switch ON 2. Compare the sight glass to the following chart. Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 51 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 41: Identifying Sight Glass Of Cooler Unit Refrigerant Liquid Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. AMOUNT OF REFRIGERANT - SYMPTOM CHART Amount of Item Symptom Refrigerant Corrective Procedures 1. Check for gas leakage and repair if necessary 2. Add refrigerant until bubbles disappear 1 Bubbles visible Insufficient* 2 No bubbles visible Empty, insufficient or too Refer to items 3 and 4 much No temperature difference 3 between compressor inlet and outlet Empty or nearly empty Considerable temperature Correct or too 4 difference between compressor much inlet and outlet Refrigerant becomes clear 5 immediately after A/C turned OFF Too much 1. Check for gas leakage with gas leak detector and repair if necessary 2. Add refrigerant until bubbles disappear Refer to items 5 and 6 1. Drain or discharge refrigerant 2. Bleed air and supply proper amount of purified refrigerant Refrigerant foams and then 6 becomes clear immediately after Correct A/C turned OFF HINT: *: If the ambient temperature is higher than usual but cooling is sufficient, bubbles in the sight glass are permissible. NG: CHARGE REFRIGERANT Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 52 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 OK: Go to next step 2. READ VALUE OF TECHSTREAM a. Connect Techstream to the DLC3. b. Turn the ignition switch ON and turn Techstream ON. c. Select the item below in the Data List, and read the value displayed on Techstream. Air conditioning amplifier DATA LIST - AIR CONDITIONING AMPLIFIER Measurement Item / Display Diagnostic Item Normal Condition (Range) Note Regulator pressure sensor / Min.: Regulator Pressure Actual regulator pressure 0.45668 MPaG Sensor is displayed Max.: 3.29437 MPaG OK: The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C: REPLACE AIR CONDITIONING AMPLIFIER A: Go to next step 3. CHECK WIRE HARNESS (PRESSURE SENSOR - AIR CONDITIONING AMPLIFIER) a. Disconnect the A21 pressure sensor connector. b. Disconnect the E37 amplifier connector. Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 53 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 42: Identifying A21 And E37 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Measure the resistance of the wire harness side connectors. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition A21-3 (+) - E37-10 (S5-3) Below 1 ohms A21-2 (PR) - E37-9 (PRE) Below 1 ohms A21-1 (-) - E37-13 (SG-2) Below 1 ohms A21-3 (+) - Body ground 1 Mohms or higher A21-2 (PR) - Body ground 1 Mohms or higher A21-1 (-) - Body ground 1 Mohms or higher NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: Go to next step 4. CHECK AIR CONDITIONING AMPLIFIER a. Remove the air conditioning amplifier with its connectors still connected. Microsoft Tuesday, August 18, 2009 3:53:53 PM Page 54 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 43: Identifying E37 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance of the wire harness side connector. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition E37-13 (SG-2) - Body ground Below 1 ohms c. Turn the ignition switch ON. d. Measure the voltage of the wire harness side connector. Standard voltage VOLTAGE SPECIFICATION Tester Connection Specified Condition E37-10 (S5-3) - E37-13 (SG-2) 4.5 to 5.5 V NG: REPLACE AIR CONDITIONING AMPLIFIER OK: Go to next step 5. INSPECT AIR CONDITIONING PRESSURE SENSOR a. Turn the A/C switch ON. b. Disconnect the A21 sensor connector. c. Connect the three 1.5 V dry cell batteries' positive (+) lead to terminal 3 and the negative (-) lead to Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 55 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 terminal 1. Then connect the voltmeter's positive (+) lead to terminal 2 and the negative (-) lead to terminal 1. Measure the voltage. OK: The voltage changes in accordance with the refrigerant pressure as shown in the graph. Fig. 44: Measuring Resistance Between Air Conditioning Amplifier Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NG: REPLACE AIR CONDITIONING PRESSURE SENSOR OK: REPLACE AIR CONDITIONING AMPLIFIER DTC B1424/24 SOLAR SENSOR CIRCUIT (DRIVER SIDE) DESCRIPTION The solar sensor, which is installed on the upper side of the instrument panel, detects sunlight and controls the air conditioning AUTO mode. The output voltage from the solar sensor varies in accordance with the amount of sunlight. When the sunlight increases, the output voltage increases. As the sunlight decreases, the output voltage decreases. The air conditioning amplifier detects changes in the output voltage from the solar sensor. DTC DETECTION CONDITION AND TROUBLE AREA REFERENCE DTC No. DTC Detection Condition Trouble Area  B1424/24 Open or short in passenger side solar sensor circuit   Solar sensor Harness and connector between solar sensor and air conditioning amplifier Air conditioning amplifier WIRING DIAGRAM Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 56 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 45: Identifying Solar Sensor Circuit - Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE 1. READ VALUE OF TECHSTREAM a. Connect Techstream to the DLC3. b. Turn the ignition switch ON and turn Techstream ON. c. Select the item below in the Data List, and read the value displayed on Techstream. Air conditioning amplifier DATA LIST - AIR CONDITIONING AMPLIFIER Measurement Item / Display Diagnostic Item Normal Condition (Range) Note Solar Sensor Driver side solar sensor / Min.: Driver side temperature increases as (D side) 0, Max.: 255 brightness increases OK: The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C: REPLACE AIR CONDITIONING AMPLIFIER Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 57 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 A: Go to next step 2. INSPECT SOLAR SENSOR a. Remove the solar sensor. b. Measure the resistance of the sensor. Fig. 46: Identifying Solar Sensor TSD And S5 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Connect the ohmmeter's positive (+) lead to terminal 1 and the negative (-) lead to terminal 3 of the solar sensor. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 1 (S5) - 3 (TSD) Sensor exposed to electric light Except infinity ohms 1 (S5) - 3 (TSD) Sensor covered with cloth infinity ohms (No continuity) NOTE: The connection procedure for using a digital tester such as an electrical tester is shown above. When using an analog tester, connect the positive (+) lead to terminal 3 and the negative (-) lead to terminal 1 of the solar sensor. HINT: Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 58 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4   As the inspection light is moved away from the sensor, the voltage decreases. Use an incandescent light for the inspection. Position it about 30 cm (11.8 in.) from the solar sensor. NG: REPLACE SOLAR SENSOR OK: Go to next step 3. CHECK WIRE HARNESS (SOLAR SENSOR - AIR CONDITIONING AMPLIFIER) a. Disconnect the F1 sensor connector. b. Disconnect the E37 amplifier connector. Fig. 47: Identifying F1 And E37 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Measure the resistance of the wire harness side connectors. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition E37-33 (TSD) - F1-3 (TSD) Below 1 ohms E37-31 (S5-4) - F1-1 (S5) Below 1 ohms E37-33 (TSD) - Body ground 1 Mohms or higher E37-31 (S5-4) - Body ground 1 Mohms or higher NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: REPLACE AIR CONDITIONING AMPLIFIER DTC B1441/41 AIR MIX DAMPER CONTROL SERVO MOTOR CIRCUIT (PASSENGER SIDE) Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 59 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 DESCRIPTION The air mix damper servo sends pulse signals to indicate the damper position to the air conditioning amplifier. The air conditioning amplifier activates the motor (normal or reverse) based on these signals to move the air mix damper (passenger seat) to the appropriate position. This adjusts the amount of air passing through the heater core after passing the evaporator and controls the temperature of the blown air. HINT: Confirm that there are no mechanical problems because this DTC can be output when either a damper link or damper is mechanically locked. DTC DETECTION CONDITION AND TROUBLE AREA REFERENCE DTC No. DTC Detection Condition Trouble Area  B1441/41 Air mix damper position does not change even if air conditioning amplifier operates air mix control servo motor   Air mix control servo motor Air conditioning harness Air conditioning amplifier WIRING DIAGRAM Fig. 48: Identifying Air Mix Damper Control Servo Motor Circuit - Wiring Diagram (Passenger Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE 1. READ VALUE OF TECHSTREAM a. Connect Techstream to the DLC3. b. Turn the ignition switch ON and turn Techstream ON. c. Select the items below in the Data List, and read the value displayed on Techstream. Air conditioning amplifier DATA LIST - AIR CONDITIONING AMPLIFIER Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 60 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Item Measurement Item / Display (Range) Normal Condition Air Mix Servo Targ Pulse (P) Passenger side air mix servo motor target pulse / Min.: 0, Max.: 255 Customized value displayed Diagnostic Note - OK: The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from PROBLEM SYMPTOMS TABLE) B OK (Checking from DTC) C B: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C: REPLACE AIR CONDITIONING AMPLIFIER A: Go to next step 2. REPLACE AIR MIX CONTROL SERVO MOTOR HINT: Since the servo motor cannot be tested when it is removed from the vehicle, replace the servo motor with a normal one and check that the condition returns to normal. OK: Same problem does not occur. NG: REPAIR OR REPLACE AIR CONDITIONING HARNESS ASSEMBLY OK: SYSTEM IS OK DTC B1442/42 AIR INLET DAMPER CONTROL SERVO MOTOR CIRCUIT DESCRIPTION The damper servo (air inlet control) sends pulse signals to indicate the damper position to the air conditioning amplifier. The air conditioning amplifier activates the motor (normal or reverse) based on these signals to move the air inlet control damper to the appropriate position, which controls the intake air settings (FRESH, FRESH / RECIRCULATION and RECIRCULATION). Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 61 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 HINT: Confirm that there are no mechanical problems because this DTC can be output when either a damper link or damper is mechanically locked. DTC DETECTION CONDITION AND TROUBLE AREA REFERENCE DTC No. DTC Detection Condition Trouble Area  B1442/42 Air inlet damper position does not change even if air conditioning amplifier operates air inlet damper control servo motor   Air inlet control servo motor Air conditioning harness Air conditioning amplifier WIRING DIAGRAM Fig. 49: Identifying Air Inlet Damper Control Servo Motor Circuit - Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE 1. READ VALUE OF TECHSTREAM a. Connect Techstream to the DLC3. b. Turn the ignition switch ON and turn Techstream ON. c. Select the items below in the Data List, and read the value displayed on Techstream. Air conditioning amplifier DATA LIST - AIR CONDITIONING AMPLIFIER Measurement Item / Display Item Normal Condition (Range) Air Inlet Damper Air inlet damper target pulse / Min.: Customized value Targ Pulse 0, Max.: 255 displayed Diagnostic Note - OK: Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 62 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from PROBLEM SYMPTOMS TABLE) B OK (Checking from DTC) C B: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C: REPLACE AIR CONDITIONING AMPLIFIER A: Go to next step 2. REPLACE DAMPER SERVO SUB-ASSEMBLY HINT: Since the servo motor cannot be tested when it is removed from the vehicle, replace the servo motor with a normal one and check that the condition returns to normal. OK: Same problem does not occur. NG: REPAIR OR REPLACE AIR CONDITIONING HARNESS ASSEMBLY OK: SYSTEM IS OK DTC B1443/43 AIR OUTLET DAMPER CONTROL SERVO MOTOR CIRCUIT DESCRIPTION The damper servo sends pulse signals to indicate the damper position to the air conditioning amplifier. The air conditioning amplifier activates the motor (normal or reverse) based on these signals to move the mode damper to the appropriate position, which controls the air outlet modes. HINT: Confirm that there are no mechanical problems because this DTC can be output when either a damper link or damper is mechanically locked. DTC DETECTION CONDITION AND TROUBLE AREA REFERENCE DTC No. DTC Detection Condition Trouble Area Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 63 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4  B1443/43 Air outlet damper position does not change even if air conditioning amplifier operates air outlet damper control servo motor   Air outlet control servo motor Air conditioning harness Air conditioning amplifier WIRING DIAGRAM Fig. 50: Identifying Air Outlet Damper Control Servo Motor Circuit - Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE 1. READ VALUE OF TECHSTREAM a. Connect Techstream to the DLC3. b. Turn the ignition switch ON and turn Techstream ON. c. Select the items below in the Data List, and read the value displayed on Techstream. Air conditioning amplifier DATA LIST - AIR CONDITIONING AMPLIFIER Item Measurement Item / Display (Range) Normal Condition Air Outlet Servo Pulse (D) Air outlet servo motor target pulse / Min.: 0, Max.: 255 Customized value displayed Diagnostic Note - OK: The display is as specified in the normal condition column. Result Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 64 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 RESULT REFERENCE Result Proceed to NG A OK (Checking from PROBLEM SYMPTOMS TABLE) B OK (Checking from DTC) C B: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C: REPLACE AIR CONDITIONING AMPLIFIER A: Go to next step 2. REPLACE MODE DAMPER SERVO SUB-ASSEMBLY HINT: Since the servo motor cannot be tested when it is removed from the vehicle, replace the servo motor with a normal one and check that the condition returns to normal. OK: Same problem does not occur. NG: REPAIR OR REPLACE AIR CONDITIONING HARNESS ASSEMBLY OK: SYSTEM IS OK DTC B1446/46 AIR MIX DAMPER CONTROL SERVO MOTOR CIRCUIT (DRIVER SIDE) DESCRIPTION The air mix damper servo sends pulse signals to indicate the damper position to the air conditioning amplifier. The air conditioning amplifier activates the motor (normal or reverse) based on these signals to move the air mix damper (driver seat) to the appropriate position. This adjusts the amount of air passing through the heater core after passing the evaporator and controls the temperature of the blown air. HINT: Confirm that there are no mechanical problems because this DTC can be output when either a damper link or damper is mechanically locked. DTC DETECTION CONDITION AND TROUBLE AREA REFERENCE DTC No. DTC Detection Condition Trouble Area  Air mix control servo motor Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 65 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4  B1446/46 Air mix damper position does not change even if air conditioning amplifier operates air mix control servo motor  Air conditioning harness Air conditioning amplifier WIRING DIAGRAM Fig. 51: Identifying Air Mix Damper Control Servo Motor Circuit - Wiring Diagram (Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE 1. READ VALUE OF TECHSTREAM a. Connect Techstream to the DLC3. b. Turn the ignition switch ON and turn Techstream ON. c. Select the items below in the Data List, and read the value displayed on Techstream. Air conditioning amplifier DATA LIST - AIR CONDITIONING AMPLIFIER Item Measurement Item / Display (Range) Normal Condition Air Mix Servo Targ Pulse (D) Driver side air mix servo motor target pulse / Min.: 0, Max.: 255 Customized value displayed Diagnostic Note - OK: The display is as specified in the normal condition column. Result Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 66 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 RESULT REFERENCE Result Proceed to NG A OK (Checking from PROBLEM SYMPTOMS TABLE) B OK (Checking from DTC) C B: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C: REPLACE AIR CONDITIONING AMPLIFIER A: Go to next step 2. REPLACE AIR MIX CONTROL SERVO MOTOR HINT: Since the servo motor cannot be tested when it is removed from the vehicle, replace the servo motor with a normal one and check that the condition returns to normal. OK: Same problem does not occur. NG: REPAIR OR REPLACE AIR CONDITIONING HARNESS OK: SYSTEM IS OK DTC B1451/51 COMPRESSOR SOLENOID CIRCUIT DESCRIPTION In this circuit, the compressor receives a refrigerant compression demand signal from the air conditioning amplifier. Based on this signal, the compressor changes the degree of refrigerant compression. DTC DETECTION CONDITION AND TROUBLE AREA REFERENCE DTC No. DTC Detection Condition Trouble Area  Open or short in solenoid of externally B1451/51 changeable compressor circuit   A/C compressor* Wire harness and connector between air conditioning amplifier and A/C compressor* Air conditioning amplifier HINT: *: Compressor and pulley for 2AZ-FE, compressor and magnetic clutch for 2GR-FE WIRING DIAGRAM Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 67 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 52: Identifying Compressor Solenoid Circuit - Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE 1. READ VALUE OF TECHSTREAM a. Connect Techstream to the DLC3. b. Turn the ignition switch ON and turn Techstream ON. c. Select the items below in the Data List, and read the value displayed on Techstream. Air conditioning amplifier DATA LIST - AIR CONDITIONING AMPLIFIER Measurement Item / Diagnostic Item Normal Condition Display (Range) Note Regulator control Value changes between 0 A and 0.997 A Regulator current / Min.: 0 A in accordance with A/C compressor Control Current Max.: 0.997 A operation OK: The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C: REPLACE AIR CONDITIONING AMPLIFIER A: Go to next step Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 68 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 2. INSPECT A/C COMPRESSOR a. Disconnect the A/C compressor clutch connector. Fig. 53: Identifying A/C Compressor Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance of the connector. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 1 (SOL-) - 2 (SOL+) 25°C (77°F) 10.1 to 11.1 ohms NG: REPLACE A/C COMPRESSOR OK: Go to next step 3. CHECK WIRE HARNESS (A/C COMPRESSOR - AIR CONDITIONING AMPLIFIER) a. Disconnect the B23 A/C compressor connector. b. Disconnect the E37 amplifier connector. Fig. 54: Identifying B23 And E37 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 69 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 c. Measure the resistance of the wire harness side connectors. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition B23-2 (SOL+) - E37-2 (SOL+) Below 1 ohms B23-2 (SOL+) - Body Ground 1 Mohms or higher NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: Go to next step 4. CHECK WIRE HARNESS (A/C COMPRESSOR - BODY GROUND) a. Disconnect the B23 A/C compressor connector. Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 70 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 55: Identifying B23 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance of the wire harness side connector. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition B23-1 (SOL-) - Body ground Below 1 ohms NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: REPLACE AIR CONDITIONING AMPLIFIER DTC B1497/97 BUS IC COMMUNICATION MALFUNCTION Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 71 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 DESCRIPTION The air conditioning harness connects the air conditioning amplifier and the servos. The air conditioning amplifier supplies power and sends operation instructions to each servo through the air conditioning harness. Each servo sends damper position information to the air conditioning amplifier. DTC DETECTION CONDITION AND TROUBLE AREA REFERENCE DTC No. DTC Detection Condition Trouble Area  B1497/97 Communication line error or open  Air conditioning harness Air conditioning amplifier WIRING DIAGRAM Fig. 56: Identifying BUS IC Communication Malfunction Circuit - Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE 1. CHECK AIR CONDITIONING AMPLIFIER a. Remove the air conditioning amplifier with its connectors still connected. Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 72 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 57: Identifying C1 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance of the wire harness side connector. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition c1 - 2 (BUB G) - Body ground Below 1 ohms NG: CHECK GROUND LINE AND AIR CONDITIONING AMPLIFIER OK: Go to next step 2. CHECK AIR CONDITIONING AMPLIFIER a. Remove the air conditioning amplifier with its connectors still connected. Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 73 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 58: Identifying C1 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the voltage of the wire harness side connector. Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition c1 - 2 (BUBG) - c1-4 (B BUS) Ignition switch ON 11 to 13 V c1 - 2 (BUBG) - c1-3 (BUS) Ignition switch ON Pulse generation NG: REPLACE AIR CONDITIONING AMPLIFIER OK: REPLACE AIR CONDITIONING HARNESS ASSEMBLY DTC B1499/99 MULTIPLEX COMMUNICATION CIRCUIT DESCRIPTION The air conditioning amplifier communicates data with the ECM and combination meter through the CAN communication system. DTC DETECTION CONDITION AND TROUBLE AREA REFERENCE DTC No. DTC Detection Condition Trouble Area   B1499/99 Open in CAN communication line   Air conditioning amplifier ECM Combination meter CAN communication line WIRING DIAGRAM Fig. 59: Identifying Multiplex Communication Circuit - Wiring Diagram Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 74 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE 1. CHECK DTC a. Clear the DTC (see DTC CHECK / CLEAR ). b. Read the DTC (see DTC CHECK / CLEAR ). Result RESULT REFERENCE Result Proceed to DTC (B1499/99) is output A (see CAN COMMUNICATION SYSTEM ) DTC (B1499/99) is not output B B: SYSTEM IS OK A: GO TO CAN COMMUNICATION SYSTEM AIR CONDITIONING CONTROL PANEL DOES NOT OPERATE DESCRIPTION This circuit consists of the air conditioning control and the air conditioning amplifier. When the air conditioning control is operated, signals are transmitted to the air conditioning amplifier through the LIN communication system. If the LIN communication system malfunctions, the air conditioning amplifier does not operate even if the air conditioning control is operated. WIRING DIAGRAM Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 75 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 60: Identifying Air Conditioning Control Panel - Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE 1. CHECK WIRE HARNESS (AIR CONDITIONING CONTROL ASSEMBLY - BODY GROUND) a. Disconnect the air conditioning control assembly connector. Fig. 61: Identifying E23 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance of the wire harness side connector. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition E23-7 (GND) - Body ground Below 1 ohms Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 76 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: Go to next step 2. CHECK WIRE HARNESS (AIR CONDITIONING CONTROL ASSEMBLY - BATTERY) a. Disconnect the E23 air conditioning control assembly connector. Fig. 62: Identifying E23 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the voltage of the wire harness side connector. Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition E23-7 (GND) - E23-2 (IG+) Ignition switch ON 10 to 14 V NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: Go to next step 3. CHECK WIRE HARNESS (AIR CONDITIONING AMPLIFIER - AIR CONDITIONING CONTROL) a. Disconnect the E23 control connector. b. Disconnect the E37 amplifier connector. Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 77 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 63: Identifying E23 And E37 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Measure the resistance of the wire harness side connectors. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition E37-37 (LIN1) - E23-11 (LIN1) Below 1 ohms NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: Go to next step 4. REPLACE AIR CONDITIONING CONTROL ASSEMBLY a. Replace the air conditioning control with a new or properly functioning one. b. Operate the air conditioning control to check that it functions properly. Result RESULT REFERENCE Result Proceed to Air conditioning control malfunctions A Air conditioning control functions properly B Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 78 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 B: END (AIR CONDITIONING CONTROL ASSEMBLY IS FAULTY) A: REPLACE AIR CONDITIONING AMPLIFIER BLOWER MOTOR CIRCUIT DESCRIPTION The blower motor is operated by signals from the air conditioning amplifier. Blower motor speed signals are transmitted in accordance with changes in the duty ratio. Fig. 64: Identifying Blower Motor Speed Signals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WIRING DIAGRAM Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 79 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 65: Identifying Blower Motor Circuit - Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE 1. PERFORM ACTIVE TEST BY TECHSTREAM a. Connect Techstream to the DLC3. b. Turn the ignition switch ON and turn Techstream ON. Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 80 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 c. Select the item below in the Active Test, and then check that the blower motor operates. Air conditioning amplifier DATA LIST - AIR CONDITIONING AMPLIFIER Item Test Details / Display Diagnostic Note Blower Motor Blower motor / Min.: 0, Max.: 31 Result RESULT REFERENCE Result Proceed to NG (blower motor does not operate) A NG (blower motor operates but does not change speed) B OK C B: Go to step 6 C: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE A: Go to next step 2. INSPECT FUSE (HTR) a. Remove the HTR H-fuse from the engine room No. 2 relay block. b. Measure the resistance of the H-fuse. Standard resistance: Below 1 ohms NG: REPLACE FUSE OK: Go to next step 3. CHECK WIRE HARNESS (BLOWER MOTOR - BODY GROUND) a. Disconnect the E53 motor connector. Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 81 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 66: Identifying E53 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance of the wire harness side connector. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition E53-1 (GND) - Body ground Below 1 ohms NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: Go to next step 4. CHECK WIRE HARNESS (BLOWER MOTOR - BATTERY) a. Disconnect the E53 motor connector. Fig. 67: Identifying E53 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the voltage of the wire harness side connector. Standard voltage VOLTAGE SPECIFICATION Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 82 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Tester Connection Condition Specified Condition E53-3 (+B) - Body ground Ignition switch ON 10 to 14 V NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: Go to next step 5. CHECK BLOWER W/ FAN MOTOR SUB-ASSEMBLY a. Disconnect the E37 amplifier connector. b. Connect the E53 motor connector. Fig. 68: Connecting E53 Blower Motor Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Measure the voltage of the connector. Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition E53-2 (SI) - Body ground Ignition switch ON 4.5 to 5.5 V NG: REPLACE BLOWER W/ FAN MOTOR SUB-ASSEMBLY OK: Go to next step 6. CHECK WIRE HARNESS (AIR CONDITIONING AMPLIFIER - BODY GROUND) a. Disconnect the E37 amplifier connector. Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 83 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 69: Identifying E37 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the voltage of the wire harness side connector. Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition Ignition switch ON E37-23 (BLW) - Body ground 4.5 to 5.5 V Blower switch OFF NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: Go to next step 7. CHECK AIR CONDITIONING AMPLIFIER a. Remove the air conditioning amplifier with its connectors still connected. b. Check the waveform of the amplifier connector. OK: Waveform is as shown in the illustration. Fig. 70: Blower Motor Control Signal Waveform Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 84 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 HINT: The waveform varies with the blower level. ITEM CHART Item Content Tester Connection BLW (E37-23) - GND (E37-14) Tool Setting 1 V/DIV, 500 µsec./DIV. Condition Ignition switch ON Blower switch LO NG: REPLACE AIR CONDITIONING AMPLIFIER OK: REPLACE BLOWER W/ FAN MOTOR SUB-ASSEMBLY COMPRESSOR CIRCUIT DESCRIPTION When the A/C switch is turned on, the magnetic clutch ON signal is sent from the air conditioning amplifier. Then the MG CLT relay turns on to operate the magnetic clutch. WIRING DIAGRAM Fig. 71: Identifying Compressor Circuit - Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE 1. PERFORM ACTIVE TEST BY TECHSTREAM a. Connect Techstream to the DLC3. b. Turn the ignition switch ON and turn Techstream ON. c. Select the item below in the Active Test and then check that the compressor magnetic relay operates. Air conditioning amplifier Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 85 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 DATA LIST - AIR CONDITIONING AMPLIFIER Item Test Details / Display (Range) Diagnostic Note Magnetic Clutch Relay Magnetic clutch relay / OFF, ON Operating sound can be heard OK: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG: Go to next step 2. INSPECT FUSE (ECU-IG1) a. Remove the ECU-IG1 fuse from the instrument panel junction block. b. Measure the resistance of the fuse. Standard resistance: Below 1 ohms NG: REPLACE FUSE OK: Go to next step 3. INSPECT MAGNETIC CLUTCH RELAY (Marking: MG CLT) a. Remove the magnetic clutch relay from the engine room No. 1 relay block. Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 86 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 72: Identifying Magnetic Clutch Relay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance of the relay. Standard resistance RESISTANCE SPECIFICATION Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 87 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Tester Connection Specified Condition 3-5 10 kohms or higher 3-5 Below 1 ohms (when battery voltage is applied to terminals 1 and 2) NG: REPLACE MAGNETIC CLUTCH RELAY OK: Go to next step 4. CHECK WIRE HARNESS (AIR CONDITIONING AMPLIFIER - BATTERY) a. Disconnect the E37 amplifier connector. Fig. 73: Identifying E37 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the voltage of the wire harness side connector. Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition E37-20 (MGC) - Body ground Ignition switch ON 10 to 14 V E37-20 (MGC) - Body ground Ignition switch OFF Below 1 V NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: Go to next step 5. CHECK AIR CONDITIONING AMPLIFIER (MGC VOLTAGE) a. Remove the air conditioning amplifier with its connectors still connected. Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 88 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 74: Identifying E37 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the voltage of the connector. Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition E37-20 (MGC) - Body ground Ignition switch ON A/C switch OFF 10 to 14 V E37-20 (MGC) - Body ground Ignition switch ON A/C switch ON Below 1.5 V NG: REPLACE AIR CONDITIONING AMPLIFIER OK: Go to next step 6. CHECK MAGNETIC CLUTCH a. Disconnect the B47 magnetic clutch connector. Fig. 75: Identifying Magnetic Clutch Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the battery's positive (+) lead to terminal 3 of the magnetic clutch and the negative (-) lead to the body ground. OK: Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 89 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Magnetic clutch is engaged. NG: REPLACE MAGNETIC CLUTCH OK: REPAIR OR REPLACE WIRE HARNESS (MAGNETIC CLUTCH - ECU-IG1) IG POWER SOURCE CIRCUIT DESCRIPTION This is the main power source supplied to the air conditioning amplifier when the ignition switch is ON (IG). This power source is used for operating components, such as the air conditioning amplifier and servo motors. WIRING DIAGRAM Fig. 76: Identifying IG Power Source Circuit - Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE 1. INSPECT FUSE (ECU-IG2) a. Remove the ECU-IG2 fuse from the instrument panel junction block. b. Measure the resistance of the fuse. Standard resistance: Below 1 ohms NG: REPLACE FUSE OK: Go to next step 2. CHECK WIRE HARNESS (AIR CONDITIONING AMPLIFIER - BATTERY) a. Disconnect the E37 amplifier connector. Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 90 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 77: Identifying E37 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the voltage of the wire harness side connector. Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition E37-1 (IG+) - Body ground Ignition switch ON 10 to 14 V NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: Go to next step 3. CHECK WIRE HARNESS (AIR CONDITIONING AMPLIFIER - BODY GROUND) a. Disconnect the E37 amplifier connector. Fig. 78: Identifying E37 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance of the wire harness side connector. Standard resistance RESISTANCE SPECIFICATION Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 91 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Tester Connection Specified Condition E37-14 (GND) - Body ground Below 1 ohms NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE BACK-UP POWER SOURCE CIRCUIT DESCRIPTION This is the back-up power source circuit for the air conditioning amplifier. Power is supplied even when the ignition switch is turned OFF and is used for functions such as the diagnostic trouble code memory. WIRING DIAGRAM Fig. 79: Identifying Back-Up Power Source Circuit - Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE 1. INSPECT FUSE (ECU-B2) a. Remove the ECU-B2 fuse from the engine room No. 2 relay block. b. Measure the resistance of the fuse. Standard resistance: Below 1 ohms NG: REPLACE FUSE OK: Go to next step 2. CHECK WIRE HARNESS (AIR CONDITIONING AMPLIFIER - BATTERY) a. Disconnect the E37 amplifier connector. Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 92 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 80: Identifying E37 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the voltage of the wire harness side connector. Standard voltage VOLTAGE SPECIFICATION Tester Connection Specified Condition E37-21 (B) - Body ground 10 to 14 V NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: Go to next step 3. CHECK WIRE HARNESS (AIR CONDITIONING AMPLIFIER - BODY GROUND) a. Disconnect the E37 amplifier connector. Fig. 81: Identifying E37 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance of the wire harness side connector. Standard resistance RESISTANCE SPECIFICATION Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 93 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Tester Connection Specified Condition E37-14 (GND) - Body ground Below 1 ohms NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AIR CONDITIONING SYSTEM (FOR MANUAL AIR CONDITIONING SYSTEM) PRECAUTION 1. 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. NOTE: If the engine speed exceeds 2,000 rpm, the A/C compressor may be damaged. 2. DO NOT HANDLE REFRIGERANT IN ENCLOSED AREAS OR NEAR OPEN FLAMES Fig. 82: Precaution For Handle Refrigerant In Enclosed Area Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. ALWAYS WEAR EYE PROTECTION 4. BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN YOUR EYES OR ON YOUR SKIN If liquid refrigerant gets in your eyes or on your skin: a. Wash the area with lots of cold water. CAUTION: Do not rub your eyes or skin. Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 94 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 b. Apply clean petroleum jelly to the skin. c. Go immediately to a physician or hospital for professional treatment. Fig. 83: Precaution For Liquid Refrigerant Eyes On Skin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. NEVER HEAT CONTAINER OR EXPOSE IT TO OPEN FLAME 6. BE CAREFUL NOT TO DROP CONTAINER OR SUBJECT IT TO PHYSICAL SHOCKS 7. DO NOT OPERATE COMPRESSOR WITH INSUFFICIENT REFRIGERANT IN REFRIGERANT SYSTEM If there is not enough refrigerant in the refrigerant system, oil lubrication will be insufficient and compressor burnout may occur. Necessary care should be taken to avoid this. Fig. 84: Identifying Correct And Incorrect Connection Of Valves Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATING Open and close only the low pressure valve. Opening and closing the high pressure valve could cause the charging cylinder to rupture. 9. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT If the refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy and Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 95 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 engine overheating. 10. DO NOT OPERATE ENGINE AND COMPRESSOR WITHOUT REFRIGERANT NOTE: This may damage the inside of the compressor. PARTS LOCATION Fig. 85: Identifying Air Conditioning System Components Location (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 96 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 86: Identifying Air Conditioning System Components Location (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Microsoft Tuesday, August 18, 2009 3:53:54 PM Page 97 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 87: Identifying Air Conditioning System Components Location (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SYSTEM DIAGRAM Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 98 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 88: Identifying Air Conditioning System Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Communication table COMMUNICATION CHART Sender Receiver Air conditioning amplifier ECM Combination meter assembly Air conditioning amplifier ECM Air conditioning amplifier Signal A/C compressor control signal Idle up request signal External variable control solenoid current signal Cooling fan motor driving request signal Ambient temperature signal Vehicle speed signal Ambient temperature signal Engine revolution speed signal Engine coolant temperature signal A/C control cut signal Variable control prohibition signal Communication Line CAN CAN CAN SYSTEM DESCRIPTION 1. GENERAL a. The air conditioning system has the following features:  The air conditioning amplifier controls the operation of parts, such as the A/C compressor, automatically in accordance with the operating conditions of the air conditioning system. 2. MODE POSITION AND DAMPER OPERATION Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 99 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 89: Mode Position And Damper Operation Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DAMPER POSITION OPERATION CHART Control Control Damper Operation Damper Position Position FRESH A Brings in fresh air. Air Inlet Control Damper RECIRC B Recirculates internal air. Air Mix Varies the mixture ratio of fresh air and the recirculation air COOL to Control Film C, D, E in order to regulate the temperature continuously from HOT HOT Damper to COOL. FACE 1, J, L, R Air blows out of center registers and side registers. Air mainly blows out of center registers, side registers, and BI-LEVEL 1, O, M, Q footwell register ducts. Air mainly blows out of front and rear footwell register FOOT H, K, N, P ducts. In addition, air blows out slightly from front and side Mode Control defrosters, and side registers. Film Damper Air mainly blows out of front and side defrosters to defrost FOOT/DEF G, K, N, Q windshield. Air also blows out from front and rear footwell register ducts, and side registers. Air blows out of front and side defrosters and side registers DEF F, K, N, R to defrost windshield. 3. AIR OUTLET AND AIRFLOW VOLUME Fig. 90: Identifying Air Outlet And Airflow Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 100 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. The circle size (O) indicates the proportion of the flow volume. Fig. 91: Air Outlet Position Symbol Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HOW TO PROCEED WITH TROUBLESHOOTING HINT:   Use these procedures to troubleshoot the air conditioning system. *: Use Techstream. 1. VEHICLE BROUGHT TO WORKSHOP 2. CUSTOMER PROBLEM ANALYSIS AND SYMPTOM CHECK 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. 4. CHECK CAN COMMUNICATION SYSTEM* a. Use Techstream to check if the CAN communication system is functioning. Result RESULT REFERENCE Result Proceed to CAN DTC is not output A CAN DTC is output B B: Go to CAN COMMUNICATION SYSTEM Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 101 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 A: Go to next step 5. CHECK DTC* a. Check for DTCs and write down any DTCs that are output. b. Clear the DTCs. c. Recheck for DTCs. Based on the DTCs output above, try to cause output of the air conditioning system DTC by simulating the operation indicated by the DTC. Result RESULT REFERENCE Result Proceed to DTC is not output A DTC is output B B: Go to step 8 A: Go to next step 6. REFER TO PROBLEM SYMPTOMS TABLE Result RESULT REFERENCE Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B B: Go to step 8 A: Go to next step 7. OVERALL ANALYSIS AND TROUBLESHOOTING* a. DATA LIST / ACTIVE TEST (see DATA LIST / ACTIVE TEST ) b. Terminals of ECU (see TERMINALS OF ECU ) 8. ADJUST, REPAIR OR REPLACE 9. CONFIRMATION TEST NEXT: END PROBLEM SYMPTOMS TABLE HINT: Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 102 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4   Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. Inspect the fuses and relays related to this system before inspecting the suspected areas below. Air conditioning system PROBLEM SYMPTOMS CHART Symptom Suspected Area 1. ECU-IG2 fuse 2. Wire harness or No functions of A/C system connector operate 3. Air conditioning amplifier 1. HTR, ECU-IG1 fuse 2. Blower motor circuit Airflow Control: Blower 3. Blower motor motor does not operate 4. Wire harness or connector 1. Blower resistor Airflow Control: Blower 2. Blower motor motor does not change 3. Heater control (blower speed switch) Temperature Control: No cool air comes out See TERMINALS OF ECU BLOWER MOTOR CIRCUIT BLOWER MOTOR - BLOWER RESISTOR BLOWER MOTOR AIR CONDITIONING PANEL (FOR MANUAL AIR CONDITIONING SYSTEM) 1. Refrigerant volume 2. Refrigerant pressure 3. Air conditioning pressure DTC B1423/23 PRESSURE SENSOR sensor circuit CIRCUIT AIR CONDITIONING PANEL (FOR 4. Heater control base (A/C MANUAL AIR CONDITIONING switch) SYSTEM) 5. Compressor and pulley COMPRESSOR AND PULLEY (FOR 2AZ(for 2AZ-FE) FE) 6. Compressor and COMPRESSOR AND PULLEY (FOR 2GRmagnetic clutch (for 2GRFE) FE) 7. Compressor circuit COMPRESSOR CIRCUIT 8. Expansion valve 9. Air conditioning TERMINALS OF ECU amplifier 10. ECM (for 2AZ-FE) SFI SYSTEM 11. ECM (for 2GR-FE) SFI SYSTEM 12. CAN communication CAN COMMUNICATION SYSTEM Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 103 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 A/C compressor does not operate Engine idle up does not occur, or is continuos 1. ECU-IG2 fuse 2. Refrigerant pressure 3. Compressor and pulley (for 2AZ-FE) 4. Compressor and magnetic clutch (for 2GRFE) 5. Air conditioning pressure sensor circuit 6. Evaporator temperature sensor circuit 7. Air conditioning amplifier 8. ECM (for 2AZ-FE) 9. ECM (for 2GR-FE) 10. CAN communication 1. Compressor circuit 2. ECM (for 2AZ-FE) 3. ECM (for 2GR-FE) COMPRESSOR AND PULLEY (FOR 2AZFE) COMPRESSOR AND PULLEY (FOR 2GRFE) DTC B1423/23 PRESSURE SENSOR CIRCUIT DTC B1413/13 EVAPORATOR TEMPERATURE SENSOR CIRCUIT TERMINALS OF ECU SFI SYSTEM SFI SYSTEM CAN COMMUNICATION SYSTEM COMPRESSOR CIRCUIT SFI SYSTEM SFI SYSTEM TERMINALS OF ECU 1. CHECK AIR CONDITIONING AMPLIFIER Fig. 92: Identifying ECU And E36 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Measure the voltage and resistance of the connectors. HINT: Check from the rear of the connector while it is connected to the air conditioning amplifier. TERMINAL DESCRIPTION Symbols Wiring Terminal Specified Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 104 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 (Terminal No.) Color Description S5-3 (E36-7) Power supply for B - W-B GND (E36-24) pressure sensor Condition Ignition switch ON CANH (E36-8) Hi-level CAN bus V - W-B GND (E36-24) line Ignition switch ON CANL (E36-9) Lo-level CAN bus W - W-B GND (E36-24) line Ignition switch ON Ground for SG-3 (E36-23) - B - Body evaporator Body ground ground temperature sensor Air conditioning PRE (E36-12) L - G pressure sensor SG-2 (E36-10) signal Air conditioning PRE (E36-12) L - G pressure sensor SG-2 (E36-10) signal 4.5 to 5.5 V Pulse generation (see awaveform 1) Pulse generation (see bwaveform 2) Always Below 1 ohms Refrigerant pressure: normal 0.76 to 4.74 V Refrigerant pressure: Abnormal (less than 0.196 MPa [2.0 kgf/cm2 , 28 psi] Refrigerant pressure: Abnormal (more than 3.14 MPa [32 kgf/cm2 , 455 psi]) Air conditioning L - G pressure sensor signal SG-2 (E36-10) - G - Body Ground for pressure Always Body ground ground sensor Engine idling SOL+ (E36-13) A/C compressor Heater control (blower GR - W-B - GND (E36-24) operation signal switch): 1 A/C switch ON IG+ (E36-14) Y - W-B Power source (IG) Ignition switch ON GND(E36-24) Ignition switch ON SBLW (E36-21) Blower motor ON GR - W-B Heater control (blower - GND (E36-24) signal switch): 0 --> 1 Ignition switch ON Evaporator TE (E36-22) W - B temperature sensor Temperature near evaporator: SG-3 (E36-23) signal 15°C (59°F) W-B GND (E36-24) Ground for main Body Always Body ground power supply ground Ignition switch ON A/C (E36-27) P - W-B A/C switch signal GND (E36-24) A/C switch OFF --> ON Engine idling LED (E36-28) - GR - Body A/C switch A/C switch ON Body ground ground indicator signal Heater control (blower PRE (E36-12) SG-2 (E36-10) Condition Below 0.76 V 4.74 V or more Below 1 ohms Pulse generation (see cwaveform 3) 10 to 14 V 10 to 14 V --> Below 1 V 1 to 1.3 V Below 1 ohms Below 1 V --> 10 to 14 V 10 to 14 V --> Below 4 V Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 105 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 LOCK (E36-3)* - SG-2 (E36-10) W-G MGC (E36-15)* V - W-B - GND (E36-24) MGC (E36-15)* V - W-B - GND (E36-24) HINT: *:for 2GR-FE Compressor lock sensor signal Magnetic clutch relay signal Magnetic clutch relay signal switch): 0 --> 1 Ignition switch ON A/C Pulse generation switch ON Magnetic clutch (see dwaveform ON 4) Ignition switch ON Magnetic 10 to 14 V clutch OFF Ignition switch ON Magnetic Below 1 V clutch ON b. Using an oscilloscope, check waveform 1. CAN communication signal CAN COMMUNICATION SIGNAL REFERENCE Item Content Symbols (Terminal No.) CANH (E36-8) - GND (E36-24) Tool Setting 1 V/DIV., 10 µsec.//DIV. Condition Ignition switch ON HINT: The waveform varies depending on the CAN communication signal. Fig. 93: Waveform Graph (Waveform 1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using an oscilloscope, check waveform 2. CAN communication signal CAN COMMUNICATION SIGNAL REFERENCE Item Content Symbols (Terminal No.) CANL (E36-9) - GND (E36-24) Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 106 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Tool Setting Condition 1 V/DIV, 10 µmsec./DIV. Ignition switch ON HINT: The waveform varies depending on the CAN communication signal. Fig. 94: Waveform Graph (Waveform 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using an oscilloscope, check waveform 3. A/C Compressor* operation signal A/C COMPRESSOR OPERATION SIGNAL REFERENCE Item Content Symbols (Terminal No.) SOL+ (E36-13) - GND (E36-24) Tool Setting 5 V/DIV, 500 µsec./DIV. Condition Engine idling, Blower switch LO, A/C switch ON HINT: *: Compressor and pulley for 2AZ-FE, compressor and magnetic clutch for 2GR-FE Fig. 95: Waveform Graph (Waveform 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 107 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 e. Using an oscilloscope, check waveform 4. Compressor lock sensor signal* COMPRESSOR LOCK SENSOR SIGNAL REFERENCE Item Content Symbols (Terminal No.) LOCK (E36-3)* - SG-2 (E36-10) Tool Setting 500 mV/DIV, 20 msec./DIV. Condition Ignition switch ON, A/C switch ON, Magnetic clutch ON HINT: *: for 2GR-FE Fig. 96: Waveform Graph (Waveform 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DIAGNOSIS SYSTEM 1. DESCRIPTION a. Air conditioning system data and the Diagnostic Trouble Codes (DTCs) can be read through the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use Techstream to check for malfunctions and perform troubleshooting. 2. CHECK DLC3 The vehicle's ECM uses the ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 108 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 97: Identifying DLC3 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TERMINAL DESCRIPTION Symbols (Terminal No.) Terminal Description SIL (7) - SG(5) Bus "+" line CG (4) - Body ground Chassis ground SG (5) - Body ground Signal ground BAT (16) - Body ground Battery positive CANH (6) - CANL (14) CAN bus line CANH (6) - CG (4) Specified Condition Pulse generation Below 1 ohms Below 1 ohms 10 to 14 V (1) 54 to 69 ohms Ignition switch LOCK HIGH-level CAN bus line Ignition switch LOCK(1) 200 ohms or higher CANL (14) - CG (4) LOW-level CAN bus line CANH (6) - BAT (16) Condition During transmission Always Always Always Ignition switch LOCK(1) 200 ohms or higher HIGH-level CAN bus line Ignition switch LOCK(1) 6 kohms or higher Ignition switch LOCK(1) 6 kohms or higher (1) Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, other switches or doors. CANL (14) - BAT (16) LOW-level CAN bus line If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction article. DTC CHECK / CLEAR 1. CHECK DTC a. Connect Techstream to the DLC3. b. Turn the ignition switch ON and turn Techstream ON. c. Read the DTC by following the prompts on the tester screen. HINT: Refer to Techstream operator's article for further details. Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 109 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 2. CLEAR DTC a. Connect Techstream to the DLC3. b. Turn the ignition switch ON and turn Techstream ON. c. Clear the DTC by following the prompts on the tester screen. HINT: Refer to Techstream operator's article for further details. DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using Techstream to read the Data List allows the values or states of switches, sensors, actuators and other items to be read without removing any parts. This non-intrusive inspection can be very useful because intermittent conditions or signals may be discovered before parts or wiring is disturbed. Reading the Data List information early in troubleshooting is one way to save diagnostic time. a. Connect Techstream to the DLC3. b. Turn the ignition switch ON and turn Techstream ON. c. Read the DATA LIST by following the prompts on the tester. Air conditioner: DATA LIST - AIR CONDITIONER Measurement Tester Display Item/Range Normal Condition Ambient temperature Ambient Temp sensor / Min.: - 23.3°C (- Actual ambient temperature is Sensor displayed 9.94°F) Max.: 65.95°C (150.71°F) Adjusted ambient Adjusted temperature / Min.: -30.8° Ambient Temp C (-23.44°F) Max.: 50.8°C (123.44°F) Diagnostic Note Open circuit: 23.3°C (-9.94°F) Short circuit: 65.95°C (150.71°F) - Evaporator temperature Evaporator Fin sensor / Min.:-29.7°C (- Actual evaporator temperature is Thermistor 21.46°F) displayed Max.: 59.55°C (139.19°F) Open circuit: 29.7°C (-21.46° F) Short circuit: 59.55°C (139.19°F) Engine coolant Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 110 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 temperature / Min.: 1.3°C Engine Actual engine coolant temperature is (34.34°F) Coolant Temp displayed after engine warmed up Max.: 90.55°C (194.99°F) Regulator pressure Regulator sensor / Min.: -0.45668 Actual regulator pressure is displayed Pressure MPaG Sensor Max.: 3.29437 MPaG Value changes between 0 A and Regulator Regulator control current / 0.997 A in accordance with Control Min.:0A compressor and magnetic clutch Current Max.: 0.997 A operation Number of Number of trouble codes / Number of DTCs displayed Trouble Codes Min.: 0, Max.: 255 - - - - 2. PERFORM ACTIVE TEST HINT: Using Techstream to perform Active Tests allows the relay, actuator, and other items to operate without removing any parts. This non-intrusive functional inspection can be very useful because intermittent operation may be discovered before parts or wiring is disturbed. Performing Active Test early in troubleshooting is one way to save diagnostic time. Data List information can be display while performing Active Test. a. Connect Techstream to the DLC3. b. Turn the ignition switch ON and turn Techstream ON. c. Perform the ACTIVE TEST by following the prompts on the tester. Air conditioner: ACTIVE TEST - AIR CONDITIONER Tester Display Test Part Control Range Diagnostic Note Magnetic Clutch Relay Magnetic clutch relay OFF, ON Operating sound can be heard DIAGNOSTIC TROUBLE CODE CHART HINT: When the air conditioning system functions properly, DTC B1400/00 is output. Air Conditioning system DIAGNOSTIC TROUBLE CODE CHART DTC No. Detection Item B1412/12 Ambient Temperature Trouble Area Memory Memorized (8.5 min. or Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 111 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Sensor Circuit      B1413/13 Evaporator Temperature Sensor Circuit    B1422/22 *1 Compressor Lock Sensor Circuit      B1423/23 Pressure Sensor Circuit   Ambient temperature more) sensor Wire harness between ambient temperature sensor and combination meter assembly Combination meter assembly Air conditioning amplifier CAN communication line Memorized (8.5 min. or No. 1 cooler more) thermistor (Evaporator temperature sensor) Wire harness between No. 1 cooler thermistor (evaporator temperature sensor) and air conditioning amplifier Air conditioning amplifier Compressor and magnetic clutch Compressor and magnetic clutch drive belt Compressor lock sensor Wire harness between compressor lock sensor and air conditioning amplifier Air conditioning amplifier Air conditioning pressure sensor Harness and Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 112 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4  B1451/51 Compressor Solenoid Circuit    B1499/99 Multiplex Communication Circuit     connector between air conditioning pressure sensor and air conditioning amplifier Air conditioning amplifier A/C Compressor*2 Wire harness between air conditioning amplifier and A/C compressor*2 Air conditioning amplifier Air conditioning amplifier ECM Combination meter assembly CAN communication line HINT: *1: DTC B1422/22 (Compressor Lock Sensor Circuit) is indicated only for a currently occurring malfunction for 2GR-FE. *2: Compressor and Pulley for 2AZ-FE, Compressor and Magnetic Clutch for 2GR-FE DTC B1412/12 AMBIENT TEMPERATURE SENSOR CIRCUIT DESCRIPTION The ambient temperature sensor is installed in the front part of the condenser to detect the ambient temperature and control the air conditioner. The sensor is connected to the combination meter and detects fluctuations in the ambient temperature. This data is used for controlling the room temperature. The sensor sends a signal to the air conditioning amplifier via the combination meter. The resistance of the ambient temperature sensor changes in accordance with the ambient temperature. As the temperature decreases, the resistance increases. As the temperature increases, the resistance decreases. The air conditioning amplifier applies a voltage (5 V) to the ambient temperature sensor and reads voltage changes as changes in the resistance of the ambient temperature sensor. The combination meter sends the read signal to the air conditioning amplifier via CAN communication. DTC DETECTION CONDITION AND TROUBLE AREA REFERENCE DTC No. DTC Detection Condition Trouble Area  Ambient temperature sensor Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 113 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4  B1412/12 Open or short in ambient temperature sensor circuit    Harness and connector between ambient temperature sensor and combination meter Combination meter Air conditioning amplifier CAN communication line WIRING DIAGRAM Fig. 98: Identifying Ambient Temperature Sensor Circuit - Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE 1. READ VALUE OF TECHSTREAM a. Connect Techstream to the DLC3. b. Turn the ignition switch ON and turn Techstream ON. c. Select the item below in the Data List, and read the value displayed on Techstream. Air conditioning amplifier DATA LIST - AIR CONDITIONING AMPLIFIER Measurement Item / Display Item Normal Condition (Range) Ambient temperature sensor / Ambient Temp Min.: - 23.3°C (-9.94°F) Sensor Max.: 65.95°C (150.71°F) Diagnostic Note Open circuit: - 23.3° Actual ambient C (-9.94°F) temperature is displayed Short circuit: 65.95°C (150.71°F) OK: The display is as specified in the normal condition column. Result Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 114 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 RESULT REFERENCE Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C: REPLACE AIR CONDITIONING AMPLIFIER A: Go to next step 2. INSPECT AMBIENT TEMPERATURE SENSOR a. Remove the ambient temperature sensor. Fig. 99: Ambient Temperature Sensor Resistance Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 115 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 b. Measure the resistance of the sensor. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 1-2 10°C (50°F) 3.00 to 3.73 kohms 1-2 15°C (50°F) 2.45 to 2.88 kohms 1-2 20°C (68°F) 1.95 to 2.30 kohms 1-2 25°C (77°F) 1.60 to 1.80 kohms 1-2 30°C (86°F) 1.28 to 1.47 kohms 1-2 35°C (95°F) 1.00 to 1.22 kohms 1-2 40°C (104°F) 0.80 to 1,00 kohms 1-2 45°C (113°F) 0.65 to 0.85 kohms 1-2 50°C (122°F) 0.50 to 0.70 kohms 1-2 55°C (131°F) 0.44 to 0.60 kohms 1-2 60°C (140°F) 0.36 to 0.50 kohms NOTE:   Touching the sensor even slightly may change the resistance value. Be sure to hold the connector of the sensor. When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph ). NG: REPLACE AMBIENT TEMPERATURE SENSOR OK: Go to next step 3. CHECK WIRE HARNESS (AMBIENT TEMPERATURE SENSOR - COMBINATION METER) a. Disconnect the A17 sensor connector. b. Disconnect the E19 meter connector. Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 116 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 100: Identifying A17 And E19 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Measure the resistance of the wire harness side connectors. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 117 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 A17-2 (OT+) - E19-23 (TEMP) Below 1 ohms A17-1 (OT-) - E19-11 (TX1+) Below 1 ohms A17-2 (OT+) - Body ground 1 Mohms or higher A17-1 (OT-) - Body ground 1 Mohms or higher NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: REPLACE COMBINATION METER DTC B1413/13 EVAPORATOR TEMPERATURE SENSOR CIRCUIT DESCRIPTION The No. 1 cooler thermistor (evaporator temperature sensor) is installed on the evaporator in the air conditioning unit to detect the temperature of the cooled air that has passed through the evaporator and to control the air conditioner. It sends signals to the air conditioning amplifier. The signals change in accordance with the resistance of the No. 1 cooler thermistor (evaporator temperature sensor). As the temperature decreases, the resistance increases. As the temperature increases, the resistance decreases. The air conditioning amplifier applies a voltage (5 V) to the No. 1 cooler thermistor (evaporator temperature sensor) and reads voltage changes as changes in the resistance of the No. 1 cooler thermistor (evaporator temperature sensor). This sensor is used for frost prevention. DTC DETECTION CONDITION AND TROUBLE AREA REFERENCE DTC No. DTC Detection Condition Trouble Area  B1413/13 Open or short in evaporator temperature sensor circuit   No. 1 cooler thermistor (evaporator temperature sensor) Harness and connector between No. 1 cooler thermistor (evaporator temperature sensor) and air conditioning amplifier Air conditioning amplifier WIRING DIAGRAM Fig. 101: Identifying Evaporator Temperature Sensor Circuit - Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 118 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 INSPECTION PROCEDURE 1. READ VALUE OF TECHSTREAM a. Connect Techstream to the DLC3. b. Turn the ignition switch ON and turn Techstream ON. c. Select the item below in the Data List, and read the value displayed on Techstream. Air conditioning amplifier DATA LIST - AIR CONDITIONING AMPLIFIER Measurement Item / Display Item Normal Condition (Range) Evaporator Fin Thermistor Diagnostic Note Open circuit: - 29.7° Evaporator temperature sensor / Actual evaporator C (-21.46°F) Min.:-29.7°C (-21.46°F) temperature is displayed Short circuit: 59.55° Max.: 59.55°C (139.19°F) C (139.19°F) OK: The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C: REPLACE AIR CONDITIONING AMPLIFIER A: Go to next step 2. INSPECT NO. 1 COOLER THERMISTOR (EVAPORATOR TEMPERATURE SENSOR) a. Remove the No. 1 cooler thermistor. Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 119 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 102: Evaporator Temperature Sensor Resistance Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance of the thermistor. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 1-2 -10°C (14°F) 7.30 to 9.10 kohms 1-2 -5°C (23°F) 5.65 to 6.95 kohms 1-2 0°C (32°F) 4.40 to 5.35 kohms 1-2 5°C (41°F) 3.40 to 4.15 kohms 1-2 10°C (50°F) 2.70 to 3.25 kohms 1-2 15°C (59°F) 2.14 to 2.58 kohms 1-2 20°C (68°F) 1.71 to 2.05 kohms 1-2 25°C (77°F) 1.38 to 1.64 kohms 1-2 30°C (86°F) 1.11 to 1.32 kohms NOTE:   Touching the thermistor even slightly may change the resistance value. Be sure to hold the connector of the thermistor. When measuring, the thermistor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph ). NG: REPLACE NO. 1 COOLER THERMISTOR OK: Go to next step 3. CHECK WIRE HARNESS (NO. 1 COOLER THERMISTOR - AIR CONDITIONING Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 120 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 AMPLIFIER) a. Disconnect the E33 No. 1 cooler thermistor connector. b. Disconnect the E36 amplifier connector. Fig. 103: Identifying E33 And E36 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Measure the resistance of the wire harness side connectors. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition E33-1 - E36-22 (TE) Below 1 ohms E33-2 - E36-23 (SG-3) Below 1 ohms E33-1 - Body ground 1 Mohms or higher E33-2 - Body ground 1 Mohms or higher NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: REPLACE AIR CONDITIONING AMPLIFIER DTC B1422/22 COMPRESSOR LOCK SENSOR CIRCUIT DESCRIPTION This sensor sends 1 pulse per engine revolution to the air conditioning amplifier. If the ratio of the compressor speed divided by the engine speed is smaller than a predetermined value, the air conditioning amplifier turns the compressor off, and the indicator blinks at approximately 1 second intervals. DTC DETECTION CONDITION AND TROUBLE AREA REFERENCE DTC No. DTC Detection Condition Trouble Area Open or short in compressor lock sensor circuit All conditions below are detected for 3 seconds or more:   Compressor and magnetic clutch Compressor and magnetic clutch drive belt Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 121 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 B1422/22 1. Engine speed: 450 rpm or more 2. Ratio between engine and compressor speed deviates 20% or more in comparison to normal operation    Compressor lock sensor Wire harness between compressor lock sensor and air conditioning amplifier Air conditioning amplifier WIRING DIAGRAM Fig. 104: Identifying Compressor Lock Sensor Circuit - Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE 1. CHECK AIR CONDITIONING AMPLIFIER (LOCK SIGNAL) a. Remove the air conditioning amplifier with its connectors still connected. Fig. 105: Air Conditioning Amplifier Waveform Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check the waveform of the amplifier connector. OK: Waveform is as shown in the illustration. ITEM CHART Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 122 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Item Content Tester Connection LOCK (E36-3) - SG-2 (E36-10) Tool Setting 500 mV/DIV., 20 msec./DIV. Condition Ignition switch ON A/C switch ON Magnetic clutch ON Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C: REPLACE AIR CONDITIONING AMPLIFIER A: Go to next step 2. INSPECT COMPRESSOR LOCK SENSOR a. Disconnect the B47 compressor lock sensor connector. Fig. 106: Measuring Resistance Between Compressor Lock Sensor Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance of the sensor. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 1 (SSR+) - 2 (SSR-) 20°C (68°F) 65 to 125 ohms NG: REPLACE COMPRESSOR LOCK SENSOR Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 123 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 OK: Go to next step 3. CHECK WIRE HARNESS (COMPRESSOR LOCK SENSOR - AIR CONDITIONING AMPLIFIER) a. Disconnect the B47 compressor lock sensor connector. b. Disconnect the E36 amplifier connector. Fig. 107: Identifying B47 And E36 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Measure the resistance of the wire harness side connectors. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition B47-1 (SSR+) - E36-3 (LOCK) Below 1 ohms B47-2 (SSR-) - E36-10 (SG-2) Below 1 ohms B47-1 (SSR+) - E36-10 (SG-2) 10 kohms or higher E36-3 (LOCK) - Body ground 10 kohms or higher NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: REPLACE AIR CONDITIONING AMPLIFIER DTC B1423/23 PRESSURE SENSOR CIRCUIT DESCRIPTION This DTC is output when the refrigerant pressure is either extremely low (0.19 MPa [2.0 kgf/cm2 , 28 psi] or less) or extremely high (3.14 MPa [32.0 kgf/cm2 , 455 psi] or more). The air conditioning pressure sensor, which is installed on the pipe of the high pressure side, detects the refrigerant pressure and sends refrigerant pressure signals to the air conditioning amplifier. The air conditioning amplifier determines the pressure from the signals in accordance with the sensor characteristics, and controls the compressor accordingly. Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 124 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 DTC DETECTION CONDITION AND TROUBLE AREA REFERENCE DTC No. DTC Detection Condition Trouble Area  Open or short in air conditioning B1423/23 pressure sensor circuit   Air conditioning pressure sensor Harness and connector between air conditioning pressure sensor and air conditioning amplifier Air conditioning amplifier WIRING DIAGRAM Fig. 108: Identifying Pressure Sensor Circuit - Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE 1. CHECK REFRIGERANT a. Check the sight glass of the cooler unit refrigerant liquid pipe. 1. Prepare the vehicle in accordance with the chart below. ITEM CHART Item Condition Engine Speed 1,500 rpm Vehicle Doors Fully open Temperature Setting MAX COLD Blower Speed HI A/C Switch ON 2. Compare the sight glass to the following chart. Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 125 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 109: Identifying Sight Glass Of Cooler Unit Refrigerant Liquid Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. AMOUNT OF REFRIGERANT - SYMPTOM CHART Amount of Item Symptom Refrigerant Corrective Procedures 1. Check for gas leakage and repair if necessary 2. Add refrigerant until bubbles disappear 1 Bubbles visible Insufficient* 2 No bubbles visible Empty, insufficient or too Refer to items 3 and 4 much No temperature difference 3 between compressor inlet and outlet Empty or nearly empty Considerable temperature Correct or too 4 difference between compressor much inlet and outlet Refrigerant becomes clear 5 immediately after A/C turned OFF Too much 1. Check for gas leakage with gas leak detector and repair if necessary 2. Add refrigerant until bubbles disappear Refer to items 5 and 6 1. Drain or discharge refrigerant 2. Bleed air and supply proper amount of purified refrigerant Refrigerant foams and then 6 becomes clear immediately after Correct A/C turned OFF HINT: *: If the ambient temperature is higher than usual but cooling is sufficient, bubbles in the sight glass are permissible. NG: CHARGE REFRIGERANT Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 126 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 OK: Go to next step 2. READ VALUE OF TECHSTREAM a. Connect Techstream to the DLC3. b. Turn the ignition switch ON and turn Techstream ON. c. Select the item below in the Data List, and read the value displayed on Techstream. Air conditioning amplifier DATA LIST - AIR CONDITIONING AMPLIFIER Measurement Item / Display Diagnostic Item Normal Condition (Range) Note Regulator pressure sensor / Min.: Regulator Pressure Actual regulator pressure 0.45668 MPaG Sensor is displayed Max.: 3.29437 MPaG OK: The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C: REPLACE AIR CONDITIONING AMPLIFIER A: Go to next step 3. CHECK WIRE HARNESS (PRESSURE SENSOR - AIR CONDITIONING AMPLIFIER) a. Disconnect the A21 pressure sensor connector. b. Disconnect the E36 amplifier connector. Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 127 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 110: Identifying A21 And E36 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Measure the resistance of the wire harness side connectors. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition A21-3 (+) - E36-7 (S5-3) Below 1 ohms A21-2 (PR) - E36-12 (PRE) Below 1 ohms A21-1 (-) - E36-10 (SG-2) Below 1 ohms A21-3 (+) - Body ground 1 Mohms or higher A21-2 (PR) -Body ground 1 Mohms or higher A21-1 (-) - Body ground 1 Mohms or higher NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: Go to next step 4. CHECK AIR CONDITIONING AMPLIFIER a. Remove the air conditioning amplifier with its connectors still connected. Fig. 111: Identifying E36 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 128 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 b. Measure the resistance of the wire harness side connector. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition E36-10 (SG-2) - Body ground Below 1 ohms c. Turn the ignition switch ON. d. Measure the voltage of the wire harness side connector. Standard voltage VOLTAGE SPECIFICATION Tester Connection Specified Condition E36-7 (S5-3) - E36-10 (SG-2) 4.5 to 5.5 V NG: REPLACE AIR CONDITIONING AMPLIFIER OK: Go to next step 5. INSPECT AIR CONDITIONING PRESSURE SENSOR a. Turn the A/C switch ON. b. Disconnect the A21 sensor connector. Fig. 112: Measuring Resistance Between Air Conditioning Amplifier Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Connect the three 1.5 V dry cell batteries' positive (+) lead to terminal 3 and the negative (-) lead to terminal 1. Then connect the voltmeter's positive (+) lead to terminal 2 and the negative (-) lead to terminal 1: Measure the voltage. OK: The voltage changes in accordance with the refrigerant pressure as shown in the graph. Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 129 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 NG: REPLACE AIR CONDITIONING PRESSURE SENSOR OK: REPLACE AIR CONDITIONING AMPLIFIER DTC B1451/51 COMPRESSOR SOLENOID CIRCUIT DESCRIPTION In this circuit, the compressor receives a refrigerant compression demand signal from the air conditioning amplifier. Based on this signal, the compressor changes the degree of refrigerant compression. DTC DETECTION CONDITION AND TROUBLE AREA REFERENCE DTC No. DTC Detection Condition Trouble Area  Open or short in solenoid of externally B1451/51 changeable compressor circuit   A/C compressor* Wire harness between air conditioning amplifier and A/C compressor* Air conditioning amplifier HINT: *: Compressor and pulley for 2AZ-FE, compressor and magnetic clutch for 2GR-FE WIRING DIAGRAM Fig. 113: Identifying Compressor Solenoid Circuit - Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE 1. READ VALUE OF TECHSTREAM a. Connect Techstream to the DLC3. b. Turn the ignition switch ON and turn Techstream ON. c. Select the items below in the Data List, and read the value displayed on Techstream. Air conditioning amplifier DATA LIST - AIR CONDITIONING AMPLIFIER Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 130 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Measurement Item / Display (Range) Regulator control Regulator current / Min.:0A Control Current Max.: 0.997 A Item Normal Condition Value changes between 0 A and 0.997 A in accordance with A/C compressor operation Diagnostic Note - OK: The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C: REPLACE AIR CONDITIONING AMPLIFIER A: Go to next step 2. INSPECT A/C COMPRESSOR a. Disconnect the A/C compressor connector. Fig. 114: Identifying A/C Compressor Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance of the connector. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 131 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 1 (SOL-) - 2 (SOL+) 25°C (77°F) 10.1 to 11.1 ohms NG: REPLACE A/C COMPRESSOR OK: Go to next step 3. CHECK WIRE HARNESS (A/C COMPRESSOR - AIR CONDITIONING AMPLIFIER) a. Disconnect the B23 A/C compressor connector. b. Disconnect the E36 amplifier connector. Fig. 115: Identifying B23 And E36 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Measure the resistance of the wire harness side connectors. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition B23-2 (SOL+) - E36-13 (SOL+) Below 1 ohms B23-2 (SOL+) - Body Ground 1 Mohms or higher NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: Go to next step 4. CHECK WIRE HARNESS (A/C COMPRESSOR - BODY GROUND) a. Disconnect the B23 A/C compressor connector. Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 132 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 116: Identifying B23 A/C Compressor Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance of the wire harness side connector. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition B23-1 (SOL-) - Body ground Below 1 ohms NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: REPLACE AIR CONDITIONING AMPLIFIER DTC B1499/99 MULTIPLEX COMMUNICATION CIRCUIT DESCRIPTION The air conditioning amplifier communicates data with the ECM and combination meter through the CAN communication system. DTC DETECTION CONDITION AND TROUBLE AREA REFERENCE DTC No. DTC Detection Condition Trouble Area   B1499/99 Open in CAN communication line   Air conditioning amplifier ECM Combination meter CAN communication line WIRING DIAGRAM Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 133 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 117: Identifying Multiplex Communication Circuit - Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE 1. CHECK DTC a. Clear the DTC (see DTC CHECK / CLEAR ). b. Read the DTC (see DTC CHECK / CLEAR ). Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 134 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Result RESULT REFERENCE Result Proceed to DTC (B1499/99) is output A (see CAN COMMUNICATION SYSTEM ) DTC (B1499/99) is not output B B: SYSTEM IS OK A:GO TO CAN COMMUNICATION SYSTEM BLOWER MOTOR CIRCUIT DESCRIPTION When the heater control (blower switch) is set to position 1 or higher, the contact of the HTR relay is closed, current flows to the blower motor, and the blower motor operates. The blower motor speed can be changed by exchanging the ground and the blower resistor circuit with the heater control (blower switch). WIRING DIAGRAM Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 135 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 118: Identifying Blower Motor Circuit - Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE 1. INSPECT FUSE (HTR) a. Remove the HTR fuse from the engine room No. 2 relay block. b. Measure the resistance of the fuse. Standard resistance: Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 136 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Below 1 ohms NG: REPLACE FUSE OK: Go to next step 2. INSPECT HEATER RELAY (Marking: HTR) a. Remove the heater relay from the instrument panel junction block. Fig. 119: Identifying Heater Blower Motor Relay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance of the relay. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition 3-4 Below 1 ohms 3-5 10 kohms or higher 3-4 10 kohms or higher (when battery voltage is applied to terminals 1 and 2) 3-5 Below 1 ohms (when battery voltage is applied to terminals 1 and 2) NG: REPLACE HEATER RELAY OK: Go to next step 3. INSPECT BLOWER MOTOR a. Disconnect the E54 motor connector. b. Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 1, then check that the blower motor operates smoothly. OK: Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 137 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 The blower motor operates smoothly. Fig. 120: Inspecting Blower Motor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Measure the current. Standard current TESTER CONNECTION AND SPECIFIED CONDITION Tester Connection Condition Specified Condition E54-1 - E54-2 Blower motor operates 1 to 3A NG: REPLACE BLOWER MOTOR OK: Go to next step 4. CHECK WIRE HARNESS (HEATER CONTROL (BLOWER SWITCH) - BATTERY) a. Disconnect the E24 heater control connector. Fig. 121: Identifying E24 Heater Control Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the voltage of the wire harness side connector. Microsoft Tuesday, August 18, 2009 3:53:55 PM Page 138 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition E24-4 (LO) - Body ground Ignition switch ON 10 to 14 V NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: Go to next step 5. INSPECT HEATER CONTROL (BLOWER SWITCH) a. Remove the heater control. Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 139 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 122: Identifying Heater Control Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance of the switch. Standard resistance RESISTANCE SPECIFICATION Tester Connection Switch Position Specified Condition ALL - 5 (E) 0 10 kohms or higher 4 (LO) - 5 (E) 1 Below 1 ohms Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 140 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 4 (LO) - 5 (E) - 9 (M1) 1 to 2 4 (LO) - 5 (E) - 9 (M1) 2 4 (LO) - 5 (E) - 9 (M1) - 10 (M2) 2 to 3 4 (LO) - 5 (E) - 10 (M2) 3 4 (LO) - 5 (E) -10 (M2) -6 (HI) 3 to 4 4 (LO) - 5 (E) - 6 (HI) 4 Below 1 ohms Below 1 ohms Below 1 ohms Below 1 ohms Below 1 ohms Below 1 ohms NG: REPLACE HEATER CONTROL OK: Go to next step 6. INSPECT BLOWER RESISTOR a. Remove the blower resistor. Fig. 123: Identifying Blower Resistor Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance of the resistor. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition E55-4 (E) - E55-1 (HI) 3.12 to 3.60 ohms E55-4 (E) - E55-3 (M2) 1.45 to 1.67 ohms E55-4 (E) - E55-2 (M1) 0.52 to 0.60 ohms NG: REPLACE BLOWER RESISTOR OK: Go to next step 7. CHECK WIRE HARNESS (HEATER CONTROL (BLOWER SWITCH) - BLOWER RESISTOR) a. Disconnect the E24 heater control connector. Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 141 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 b. Disconnect the E55 blower resistor connector. Fig. 124: Identifying E24 And E55 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Measure the resistance of the wire harness side connectors. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition E24-6 (HI) - E55-1 (HI) Below 1 ohms E24-9 (M1) - E55-2 (M1) Below 1 ohms E24-10 (M2) - E55-3 (M2) Below 1 ohms E24-5 (E) - Body ground Below 1 ohms E55-4 (E) - Body ground Below 1 ohms NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: Go to next step 8. CHECK WIRE HARNESS (BLOWER RESISTOR - BLOWER MOTOR) a. Disconnect the E55 blower resistor connector. b. Disconnect the E54 motor connector. Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 142 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 125: Identifying E55 And E54 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Measure the resistance of the wire harness side connectors. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition E55-4 (E) - E54-1 Below 1 ohms NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: Go to next step 9. CHECK WIRE HARNESS (BLOWER MOTOR - BODY GROUND) a. Disconnect the E54 motor connector. Fig. 126: Identifying E54 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance of the wire harness side connector. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition E54-2 - Body ground Below 1 ohms c. Measure the voltage of the Wire harness side connector. Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 143 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 E54-2 - Body ground Ignition switch ON Heater control (blower switch) 1 10 to 14 V NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: Go to next step 10. CHECK WIRE HARNESS (AIR CONDITIONING AMPLIFIER - BATTERY) a. Disconnect the E36 amplifier connector. Fig. 127: Identifying E36 And SBLW Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the voltage of the wire harness side connector. Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition E36-21 (SBLW) - Body ground Ignition switch ON Heater control (blower switch) 0 10 to 14 V NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: Go to next step 11. CHECK WIRE HARNESS (AIR CONDITIONING AMPLIFIER - BODY GROUND) a. Disconnect the E36 amplifier connector. Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 144 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 128: Identifying E36 And GND Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance of the wire harness side connector. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition E36-24 (GND) - Body ground Below 1 ohms NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE COMPRESSOR CIRCUIT DESCRIPTION When the A/C switch is turned on, the magnetic clutch ON signal is sent from the air conditioning amplifier. Then the MG CLT relay turns on to operate the magnetic clutch. WIRING DIAGRAM Fig. 129: Identifying Compressor Circuit - Wiring Diagram Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 145 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE 1. PERFORM ACTIVE TEST BY TECHSTREAM a. Connect Techstream to the DLC3. b. Turn the ignition switch ON and turn Techstream ON. c. Select the item below in the Active Test and then check that the compressor magnetic relay operates. Air conditioning amplifier DATA LIST - AIR CONDITIONING AMPLIFIER Item Test Details / Display (Range) Diagnostic Note Magnetic Clutch Relay Magnetic clutch relay / OFF, ON Operating sound can be heard OK: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG: Go to next step 2. INSPECT FUSE (ECU-IG1) a. Remove the ECU-IG1 fuse from the instrument panel junction block. b. Measure the resistance of the fuse. Standard resistance: Below 1 ohms NG: REPLACE FUSE OK: Go to next step 3. INSPECT MAGNETIC CLUTCH RELAY (Marking: MG CLT) a. Remove the magnetic clutch relay from the engine room No. 1 relay block. Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 146 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 130: Identifying Magnetic Clutch Relay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance of the relay. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition 3-5 10 kohms or higher 3-5 Below 1 ohms (when battery voltage is applied to terminals 1 and 2) NG: REPLACE MAGNETIC CLUTCH RELAY OK: Go to next step 4. CHECK WIRE HARNESS (AIR CONDITIONING AMPLIFIER - BATTERY) a. Disconnect the E36 amplifier connector. Fig. 131: Identifying E36 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the voltage of the wire harness side connector. Standard voltage Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 147 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition E36-15 (MGC) - Body ground Ignition switch ON 10 to 14 V E36-15 (MGC) - Body ground Ignition switch OFF Below 1 V NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: Go to next step 5. CHECK AIR CONDITIONING AMPLIFIER (MGC VOLTAGE) a. Remove the air conditioning amplifier with its connectors still connected. Fig. 132: Identifying E36 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the voltage of the connector. Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition E36-15 (MGC) - Body ground Ignition switch ON A/C switch OFF 10 to 14 V E36-15 (MGC) - Body ground Ignition switch ON A/C switch ON Below 1 V NG: REPLACE AIR CONDITIONING AMPLIFIER OK: Go to next step 6. CHECK MAGNETIC CLUTCH a. Disconnect the B47 magnetic clutch connector. Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 148 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 133: Identifying Magnetic Clutch Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the battery's positive (+) lead to terminal 3 of the magnetic clutch and the negative (-) lead to the body ground. OK: Magnetic clutch is engaged. NG: REPLACE MAGNETIC CLUTCH OK: REPAIR OR REPLACE WIRE HARNESS (MAGNETIC CLUTCH - ECU-IG1) IG POWER SOURCE CIRCUIT DESCRIPTION This is the main power source supplied to the air conditioning amplifier when the ignition switch is ON. This power source is used for operating components, such as the air conditioning amplifier and servo motors. WIRING DIAGRAM Fig. 134: Identifying IG Power Source Circuit - Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 149 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 1. INSPECT FUSE (ECU-IG2) a. Remove the ECU-IG2 fuse from the instrument panel junction block. b. Measure the resistance of the fuse. Standard resistance: Below 1 ohms NG: REPLACE FUSE OK: Go to next step 2. CHECK WIRE HARNESS (AIR CONDITIONING AMPLIFIER - BATTERY) a. Disconnect the E36 amplifier connector. Fig. 135: Identifying E36 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the voltage of the wire harness side connector. Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition E36-14 (IG+) - Body ground Ignition switch ON 10 to 14 V NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: Go to next step 3. CHECK WIRE HARNESS (AIR CONDITIONING AMPLIFIER - BODY GROUND) a. Disconnect the E36 amplifier connector. Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 150 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 136: Identifying E36 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance of the wire harness side connector. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition E36-24 (GND) - Body ground Below 1 ohms NG: REPAIR OR REPLACE HARNESS AND CONNECTOR OK: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE REFRIGERANT ON-VEHICLE INSPECTION 1. INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET a. This method uses a manifold gauge set to locate problem areas. Read the manifold gauge pressure when these conditions are established. Test conditions:  Temperature at the air inlet is 30 to 35°C (86 to 95°F).  Engine is running at 1,500 rpm.  All doors are fully open.  Blower speed control switch is at HI.  A/C switch is ON. Gauge readings (Reference). Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 151 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 137: Identifying Blower Zone Graph - Pressure Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Normally functioning refrigeration system Fig. 138: Identifying Manifold Gauge Set Different Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Gauge reading PRESSURE SIDE REFRIGERANT VOLUME CHART Pressure side Refrigerant volume Low 0.15 to 0.25 MPa (1.5 to 2.5 kgf/cm2 ) High 1.37 to 1.57 MPa (14 to 16 kgf/cm2 ) 2. The A/C system periodically changes between normal and improper function due to moisture Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 152 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 in the refrigerant system. Fig. 139: Checking Refrigerant Pressure (Moisture In Refrigerant System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SYMPTOMS CHART Symptoms Probable Cause Moisture in refrigeration During operation, system freezes at pressure on low expansion valve orifice, pressure side causing temporary stop cycles between of cycle. However, normal and when melted, normal vacuum state is restored. Diagnosis   Corrective Actions Drier is overly saturated Moisture in refrigeration system freezes at expansion valve orifice and blocks refrigerant circulation 1. Replace cooler drier 2. Remove moisture from cycle by repeatedly evacuating air 3. Supply appropriate volume of new refrigerant 3. The A/C system does not function effectively due to insufficient cooling. Fig. 140: Checking Refrigerant Pressure (Insufficient Cooling) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SYMPTOMS CHART Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 153 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Symptoms   Pressure low on both low and high pressure sides Cooling performance insufficient Probable Cause Diagnosis Gas leakage from refrigeration system   Insufficient refrigerant Refrigerant leakage Corrective Actions 1. Check for gas leakage and repair if necessary 2. Supply appropriate volume of new refrigerant 3. If indicated pressure value close to 0 when connected to gauge, create vacuum after inspecting and repairing the location of leakage 4. The A/C system does not function effectively due to poor circulation of the refrigerant. Fig. 141: Checking Refrigerant Pressure (Poor Circulation Of Refrigerant) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SYMPTOMS CHART Symptoms   Probable Cause Diagnosis Pressure low on both low Refrigerant flow obstructed Condenser and high pressure sides clogged Frost exists on piping from by dirt in condenser condenser to A/C unit Corrective Actions Replace condenser 5. The A/C system does not function intermittently because the refrigerant does not circulate. Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 154 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 142: Checking Refrigerant Pressure (Refrigerant Not Circulate) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SYMPTOMS CHART Symptoms   Vacuum indicated on low pressure side, and extremely low pressure indicated on high pressure side Frost or condensation seen on piping on both sides of condenser or expansion valve Probable Cause   Diagnosis Refrigerant flow obstructed by moisture or dirt in refrigeration Refrigerant system does not Refrigerant flow circulate obstructed by gas leakage from expansion valve Corrective Actions 1. Check expansion valve refrigerant 2. Clean expansion valve by blowing air 3. Replace condenser 4. Evacuate air and charge appropriate volume of new refrigerant 5. For gas leakage from expansion valve, replace expansion valve 6. The A/C system does not function effectively due to overcharged refrigerant or insufficient cooling of the condenser. Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 155 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 143: Checking Refrigerant Pressure (Overcharged Refrigerant Or Insufficient Cooling Of Condenser) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SYMPTOMS CHART Symptoms Probable Cause Pressure extremely high on both low and high-pressure sides   Diagnosis Excessive refrigerant Cooling performance of condenser insufficient    Condenser is dirty Condenser fan motor is malfunctioning Excessive refrigerant Corrective Actions 1. Clean condenser 2. Check condenser fan motor operation 3. If 1 and 2 normal, check the amount of refrigerant and supply appropriate volume of refrigerant 7. The A/C system does not function due to air in the refrigeration system. CAUTION: The low-pressure piping may be very hot and cause serious burns. Fig. 144: Identifying Manifold Gauge Set Different Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SYMPTOMS CHART Symptoms   Probable Cause Pressure extremely high on both low and Air in high-pressure sides refrigeration Low-pressure piping system is too hot to touch Diagnosis   Air in refrigeration system Vacuum purging insufficient Corrective Actions 1. Check if compressor oil is dirty or insufficient 2. Evacuate air and charge new refrigerant Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 156 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 8. The A/C system does not function effectively due to an expansion valve malfunction. Fig. 145: Checking Refrigerant Pressure (Expansion Valve Malfunction) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SYMPTOMS CHART Probable Cause Symptoms   Pressure extremely high on both low and highpressure sides Frost or condensation on piping on low-pressure side Diagnosis  Problem with expansion valve  Excessive refrigerant in low pressure piping Expansion valve too wide open Corrective Actions Replace expansion valve 9. The A/C system does not function due to a defective compressor. Fig. 146: Checking Refrigerant Pressure (Defective Compressor) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SYMPTOMS CHART Symptoms  Probable Cause Pressure extremely high on both low and Diagnosis  Corrective Actions Compression failure Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 157 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4  high-pressure sides Pressure extremely low on high pressure side  Internal leakage in compressor Leakage from damaged valve or broken sliding parts Repair or replace compressor REPLACEMENT 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM a. Start up the engine. b. Turn the A/C switch ON. c. Operate the cooler compressor with an engine speed of approximately 1,000 rpm for 5 to 6 minutes to circulate the refrigerant and collect the compressor oil remaining in each component into the cooler compressor. d. Stop the engine. e. Recover the refrigerant from the A/C system using a refrigerant recovery unit, 2. CHARGE REFRIGERANT a. Perform vacuum purging using a vacuum pump. b. Charge refrigerant HFC-134a (R134a). SST 09985-20010 (09985-02010, 09985-02050, 09985-02060, 09985-02070, 09985-02080, 0998502090, 09985-02110, 09985-02130, 09985-02140, 09985-02150) Standard: 430+-30g(15.2+-1.1 oz.) Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 158 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 147: Charge Refrigerant Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:   Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat. Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 159 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 be checked by measuring its quantity, and not with the sight glass. 3. WARM UP ENGINE a. Warm up the engine at less than 1,850 rpm for 2 minutes or more after charging the refrigerant. NOTE: 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. 4. INSPECT FOR REFRIGERANT LEAK a. After recharging with refrigerant gas, inspect for refrigerant leak gas using a halogen leak detector. b. Perform the operation under these conditions:  Stop the engine.  Secure good ventilation (the gas leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).  Repeat the test 2 or 3 times.  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) c. Using a gas leak detector, inspect for refrigerant leak from the refrigerant lines. Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 160 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 148: Inspecting Refrigerant Leak From Refrigerant Lines Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. 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. e. 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. REFRIGERANT LINE COMPONENTS Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 161 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 149: Identifying Refrigerant Line Components With Torque Specification (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Fig. 150: Identifying Refrigerant Line Components With Torque Specification (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. AIR CONDITIONING UNIT COMPONENTS Fig. 151: Identifying Air Conditioning Unit Components With Torque Specification (1 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 162 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 152: Identifying Air Conditioning Unit Components With Torque Specification (2 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Fig. 153: Identifying Air Conditioning Unit Components (3 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 163 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 154: Identifying Air Conditioning Unit Components With Torque Specifications (4 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Fig. 155: Identifying Air Conditioning Unit Components With Torque Specifications (5 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Fig. 156: Identifying Air Conditioning Unit Components (6 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 164 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 157: Identifying Air Conditioning Unit Components With Torque Specification(7 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Fig. 158: Identifying Air Conditioning Unit Components With Torque Specification (8 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See REPLACEMENT ) 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 3. REMOVE TUBE SUB-ASSEMBLY a. Remove the bolt. b. Remove plate, as shown in the illustration. Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 165 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 159: Removing Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disconnect the suction tube and liquid tube. NOTE:   Do not use a screwdriver or similar tool to disconnect the tube. Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them. d. Remove the 2 O-rings from the suction tube and liquid tube. Fig. 160: Removing O-Rings From Suction Tube And Liquid Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. DISCONNECT INLET HEATER WATER HOSE a. Using pliers, grip the claws of the clip and slide the clip. b. Disconnect the heater water inlet hose. Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 166 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 161: Locating Heater Water Inlet And Outlet Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. DISCONNECT OUTLET HEATER WATER HOSE HINT: Disconnection of the heater water outlet hose is the same as for the heater water inlet hose. 6. REMOVE STEERING COLUMN ASSEMBLY a. Remove the steering column (see REMOVAL ). 7. REMOVE UPPER INSTRUMENT PANEL a. Remove the upper instrument panel (see REMOVAL ). 8. REMOVE LOWER INSTRUMENT PANEL a. Remove the lower instrument panel (see REMOVAL ). 9. REMOVE DEFROSTER NOZZLE ASSEMBLY a. Detach the 3 claws and remove the defroster nozzle assembly. Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 167 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 162: Installing Defroster Nozzle Assembly Lower Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY a. Fold the floor carpet back. Fig. 163: Folding Floor Carpet Back Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 168 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the clamp and disconnect the wire harness. Fig. 164: Disconnecting Clamp And Wire Harness Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the bolt, nut, screw, and instrument panel brace. Fig. 165: Identifying Instrument Panel Brace With Bolt, Nut And Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE AIR DUCT REAR a. Disconnect the 2 clamps and disconnect the wire harness. Fig. 166: Identifying Clamps Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 169 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Detach the 3 claws and remove the air duct rear. Fig. 167: Identifying Claws And Rear Air Duct Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE AIR DUCT Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 170 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 a. Detach the 2 claws and remove the air duct. Fig. 168: Identifying Claws And Air Duct Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY a. Detach the 2 clamps. b. Disconnect the connector. Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 171 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 169: Identifying Clamps To Amplifier Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the screw and amplifier. Fig. 170: Identifying Air Conditioning Amplifier Assembly Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. REMOVE DRAIN COOLER HOSE a. Remove the drain hose. Fig. 171: Locating Drain Cooler Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. REMOVE INSTRUMENT PANEL REINFORCEMENT a. Disconnect the 12 clamps. Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 172 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 172: Identifying Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 4 bolts and disconnect the ground wire. Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 173 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 173: Identifying Bolts And Ground Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 3 bolts. Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 174 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 174: Identifying Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the 6 bolts and instrument panel reinforcement. Fig. 175: Identifying Instrument Panel Reinforcement And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. REMOVE AIR CONDITIONER UNIT ASSEMBLY a. Remove the bolt, nut and A/C unit. Fig. 176: Identifying Air Conditioner Unit Assembly Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY 1. REMOVE NO. 3 HEATER TO REGISTER DUCT Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 175 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 a. Detach the 6 claws and remove the heater to register duct. Fig. 177: Identifying Heater To Register Duct And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE AIR DUCT a. Detach the 2 claws and remove the air duct. Fig. 178: Identifying Air Duct And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE AIR OUTLET CONTROL SERVO MOTOR a. Remove the 3 screws. b. Detach the evaporator case from the blower case. Fig. 179: Identifying Evaporator Case From Blower Case And Screws Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 176 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 3 screws and disconnect the connector. d. Remove the air outlet control servo motor. Fig. 180: Identifying Screws And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE AIR MIX CONTROL SERVO MOTOR a. Remove the 3 screws and disconnect the connector. b. Remove the air mix control servo motor. Fig. 181: Identifying Air Mix Control Servo Motor Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE MODE CONTROL CABLE ASSEMBLY (for Manual Air Conditioning System) a. Remove the 3 screws. b. Detach the evaporator case from the blower case. Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 177 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 182: Identifying Evaporator Case From Blower Case And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Detach the 3 claws and remove the cable. Fig. 183: Installing Mode Control Cable Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REPAIR AIRMIX DAMPER CONTROL CABLE SUB-ASSEMBLY (for Manual Air Conditioning System) a. Detach the 3 claws and remove the cable. Fig. 184: Installing Airmix Damper Control Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY Microsoft Tuesday, August 18, 2009 3:53:56 PM Page 178 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 a. Detach the screw and remove the clamp. b. Remove the heater radiator unit. Fig. 185: Identifying Heater Radiator Unit Sub-Assembly Screw And Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE COOLER EXPANSION VALVE a. Using a 4 mm hexagon wrench, remove the 2 hexagon bolts. b. Remove the cooler expansion valve and 2 O-rings from the cooler evaporator. Fig. 186: Identifying Cooler Expansion Valve And O-Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY a. Remove the 4 screws. b. Detach the 2 claws and remove the cover. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 179 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 187: Locating Screws And Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Detach the cooler thermistor clamp. d. Remove the cooler thermistor and cooler evaporator from the case. Fig. 188: Identifying Cooler Thermistor Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE EVAPORATOR TEMPERATURE SENSOR a. Disconnect the cooler thermistor clamp from the cooler evaporator. Fig. 189: Disconnecting Cooler Thermistor Clamp From Cooler Evaporator Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 180 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 1. INSTALL EVAPORATOR TEMPERATURE SENSOR NOTE: 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. a. Install the evaporator temperature sensor as shown in the illustration. Fig. 190: Installing Evaporator Temperature Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY a. Install the cooler thermistor and cooler evaporator on the case. b. Attach the temperature sensor clamp. Fig. 191: Identifying Cooler Thermistor Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Attach the 2 claws to install the cover. d. Install the 4 screws. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 181 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 192: Locating Screws And Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL COOLER EXPANSION VALVE a. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the hose joint. Compressor oil: ND-OIL 8 or equivalent b. Install the 2 O-rings to the cooler evaporator. c. Install the cooler expansion valve. Fig. 193: Identifying Cooler Expansion Valve And O-Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. 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 a. Install the heater radiator with the clamp and screw. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 182 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 194: Identifying Heater Radiator Unit Sub-Assembly Screw And Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. INSTALL AIRMIX DAMPER CONTROL CABLE SUB-ASSEMBLY (for Manual Air Conditioning System) a. Attach the 3 claws to install the cable. Fig. 195: Installing Airmix Damper Control Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. INSTALL MODE CONTROL CABLE ASSEMBLY (for Manual Air Conditioning System) a. Attach the 3 claws to install the cable. Fig. 196: Installing Mode Control Cable Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 183 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 b. Attach the evaporator case to the blower case. c. Install the cable with the 3 screws. Fig. 197: Identifying Evaporator Case From Blower Case And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. INSTALL AIR MIX CONTROL SERVO MOTOR a. Install the air mix control servo motor with the 3 screws and connect the connector. Fig. 198: Identifying Air Mix Control Servo Motor Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. INSTALL AIR OUTLET CONTROL SERVO MOTOR a. Install the air outlet control servo motor with the 3 screws and connect the connector. Fig. 199: Identifying Screws And Connector Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 184 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Attach the evaporator case to the blower case. c. Install the 3 screws. Fig. 200: Identifying Evaporator Case From Blower Case And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. INSTALL AIR DUCT a. Attach the 2 claws and install the air duct. Fig. 201: Identifying Air Duct And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. INSTALL NO. 3 HEATER TO REGISTER DUCT a. Attach the 6 claws and install the heater to register duct. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 185 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 202: Identifying Heater To Register Duct And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION 1. INSTALL AIR CONDITIONER UNIT ASSEMBLY a. Install the A/C unit with the bolt and nut. Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf) Fig. 203: Identifying Air Conditioner Unit Assembly Bolt And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL INSTRUMENT PANEL REINFORCEMENT a. Install the instrument panel reinforcement with the 6 bolts. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 186 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 204: Identifying Instrument Panel Reinforcement And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the 3 bolts. Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf) Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 187 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 205: Identifying Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install the 4 bolts and connect the ground wire. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 188 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 206: Identifying Bolts And Ground Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Attach the 12 clamps. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 189 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 207: Identifying Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL DRAIN COOLER HOSE a. Install the drain hose. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 190 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 208: Locating Drain Cooler Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY a. Install the A/C amplifier with the screw. b. Connect the connector. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 191 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 209: Identifying Air Conditioning Amplifier Assembly Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Attach the 2 clamps to the amplifier. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 192 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 210: Identifying Clamps To Amplifier Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. INSTALL AIR DUCT a. Attach the 2 claws and install the air duct. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 193 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 211: Identifying Claws And Air Duct Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. INSTALL REAR AIR DUCT a. Attach the 3 claws and install the air duct rear. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 194 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 212: Identifying Claws And Rear Air Duct Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Attach the 2 clamps and install the wire harness. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 195 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 213: Identifying Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. INSTALL NO. 1 INSTRUMENT PANEL BRACE ASSEMBLY a. Install the instrument panel brace with the bolt, nut and screw. Fig. 214: Identifying Instrument Panel Brace With Bolt, Nut And Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the clamp and connect the wire harness. Fig. 215: Identifying Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Reposition the floor carpet. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 196 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 216: Locating Floor Carpet Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. INSTALL DEFROSTER NOZZLE ASSEMBLY a. Attach the 3 claws and install the defroster nozzle assembly lower. Fig. 217: Identifying Defroster Nozzle Assembly Lower And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. INSTALL LOWER INSTRUMENT PANEL a. Install the lower instrument panel (see INSTALLATION ). 10. INSTALL UPPER INSTRUMENT PANEL a. Install the upper instrument panel (see INSTALLATION ). 11. INSTALL STEERING COLUMN ASSEMBLY a. Install the steering column (see INSTALLATION ). 12. CONNECT HEATER WATER OUTLET HOSE a. Connect the water hose and attach the clip. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 197 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 218: Locating Heater Water Inlet And Outlet Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. CONNECT HEATER WATER INLET HOSE HINT: Use the same procedures described for the water outlet hose. 14. CONNECT TUBE SUB-ASSEMBLY a. Remove the attached vinyl tape from the pipe. b. 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 c. Install the 2 O-rings on the suction tube and liquid tube. d. Connect the suction tube and liquid tube. HINT: After the connection, check that the claw of the piping clamp is engaged. e. Install the plate with the bolt. Torque: 9,8 N*m (100 kgf*cm, 7 ft.*lbf) Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 198 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 219: Installing Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 16. CHECK SRS WARNING LIGHT a. Check the SRS warning light (see DIAGNOSIS SYSTEM ). 17. REPLACE ENGINE COOLANT Refer to the following procedures (see ON-VEHICLE INSPECTION ,REPLACEMENT ). 18. 19. 20. 21. CHARGE REFRIGERANT (See REPLACEMENT ) WARM UP ENGINE (See REPLACEMENT ) INSPECT FOR COOLANT LEAK INSPECT FOR REFRIGERANT LEAK (See REPLACEMENT ) BLOWER UNIT COMPONENTS Fig. 220: Identifying Blower Unit Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 199 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE UPPER INSTRUMENT PANEL a. Remove the upper instrument panel (see REMOVAL ). 3. REMOVE LOWER INSTRUMENT PANEL a. Remove the lower instrument panel (see REMOVAL ). 4. REMOVE AIR DUCT (See REMOVAL ) 5. REMOVE AIR CONDITIONING UNIT a. Remove the air conditioning unit (see REMOVAL ). 6. REMOVE BLOWER ASSEMBLY a. Remove the 3 screws and blower. Fig. 221: Identifying Evaporator Case From Blower Case And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY 1. REMOVE HEATER TO REGISTER DUCT ASSEMBLY a. Detach the 7 claws and register duct. Fig. 222: Identifying Claws And Register Duct Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 200 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 2. REMOVE AIR FILTER CASE a. Detach the 2 claws and remove the air filter case. b. Remove the air filter. Fig. 223: Identifying Claws And Air Filter Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE AIR INLET CONTROL SERVO MOTOR (for Manual Air Conditioning System) a. Remove the 3 screws and air inlet servo motor. Fig. 224: Identifying Air Inlet Servo Motor And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE AIR INLET CONTROL SERVO MOTOR (for Automatic Air Conditioning System) a. Detach the claws and lever. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 201 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 225: Detaching Claws And Lever Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 screws and air inlet servo motor. Fig. 226: Identifying Air Inlet Servo Motor And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE BLOWER RESISTOR (for Manual Air Conditioning System) a. Remove the 2 screws and blower resistor. Fig. 227: Locating Screws And Blower Resistor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE BLOWER MOTOR a. Remove the 3 screws and blower motor. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 202 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 228: Locating Screws And Blower Motor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY 1. INSTALL BLOWER MOTOR a. Install the blower motor with the 3 screws. Fig. 229: Identifying Screws And Blower Motor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL BLOWER RESISTOR (for Manual Air Conditioning System) a. Install the blower resistor with the 2 screws. Fig. 230: Locating Screws And Blower Resistor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL AIR INLET CONTROL SERVO MOTOR (for Automatic Air Conditioning System) a. Install the air inlet servo motor with the 3 screws. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 203 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 231: Identifying Air Inlet Servo Motor And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Attach the claw to install the lever. Fig. 232: Detaching Claws And Lever Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. INSTALL AIR INLET CONTROL SERVO MOTOR (for Manual Air Conditioning System) a. Install the air inlet servo motor with the 3 screws. Fig. 233: Identifying Air Inlet Servo Motor And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. INSTALL AIR FILTER CASE a. Install the air filter. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 204 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 b. Attach the 2 claws to install the air filter case. Fig. 234: Identifying Claws And Air Filter Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. INSTALL HEATER TO REGISTER DUCT ASSEMBLY a. Attach the 7 claws to install the register duct. Fig. 235: Identifying Claws And Register Duct Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION 1. INSTALL BLOWER ASSEMBLY a. Install the blower assembly with the 3 screws. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 205 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 236: Identifying Evaporator Case From Blower Case And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL AIR CONDITIONING UNIT a. Install the air conditioning unit (see INSTALLATION ). 3. INSTALL AIR DUCT (See INSTALLATION ) 4. INSTALL LOWER INSTRUMENT PANEL a. Install the lower instrument panel (see INSTALLATION ). 5. INSTALL UPPER INSTRUMENT PANEL a. Install the upper instrument panel (see INSTALLATION ). 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 7. CHECK SRS WARNING LIGHT a. Check the SRS warning light (see DIAGNOSIS SYSTEM ). BLOWER MOTOR ON-VEHICLE INSPECTION 1. INSPECT BLOWER MOTOR (for Automatic Air Conditioning System) a. Disconnect the blower motor connector. b. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2, and then check that the motor operates smoothly. If the operation is not as specified, replace the blower motor. Fig. 237: Identifying Blower Motor Terminals (For Automatic Air Conditioning System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSPECT BLOWER MOTOR (for Manual Air Conditioning System) a. Disconnect the blower motor connector. b. Connect the positive (+) lead from the battery to terminal 2 and negative (-) lead to terminal 1, and then check that the motor operates smoothly. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 206 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 If the operation is not as specified, replace the blower motor. Fig. 238: Identifying Blower Motor Terminals (For Manual Air Conditioning System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BLOWER RESISTOR ON-VEHICLE INSPECTION 1. INSPECT BLOWER MOTOR CONTROL a. Measure the resistance of the blower resistor. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition 1-2 1.45 to 1.67 ohms 1-3 0.52 to 0.60 ohms 1-4 3.12 to 3.60 ohms Fig. 239: Identifying Blower Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the resistance is not as specified, replace the blower motor control. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 207 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 AIR INLET CONTROL SERVO MOTOR COMPONENTS Fig. 240: Identifying Air Inlet Control Servo Motor Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. REMOVE BLOWER ASSEMBLY a. Remove the blower (see REMOVAL ). 2. REMOVE AIR INLET CONTROL SERVO MOTOR (See REMOVAL ) INSPECTION 1. INSPECT AIR INLET CONTROL SERVO MOTOR (for Automatic Air Conditioning System) a. Inspect the servo motor operation. Fig. 241: Inspecting Servo Motor Operation (For Automatic Air Conditioning System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Connect the positive (+) lead from the battery to terminal 4 and negative (-) lead to terminal 5, and then check that the arm turns to the "FRESH" side smoothly. 2. Connect the positive (+) lead from the battery to terminal 5 and negative (-) lead to terminal 4, and then check that the arm turns to the "RECIRCULATION" side smoothly. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 208 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 If the operation is not as specified, replace the air inlet control servo motor. Fig. 242: Identifying Air Inlet Control Servo Motor Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSPECT AIR INLET CONTROL SERVO MOTOR (for Manual Air Conditioning System) a. Inspect the servo motor operation. Fig. 243: Inspecting Air Inlet Control Servo Motor Operation (For Manual Air Conditioning System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Connect the positive (+) lead from the battery to terminal 5 and negative (-) lead to terminal 1, and then check that the arm turns to the "FRESH" side smoothly. 2. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 5, and then check that the arm turns to the "RECIRCULATION" side smoothly, if the operation is not as specified, replace the air inlet servo motor. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 209 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 244: Identifying Air Inlet Control Servo Motor Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION 1. INSTALL AIR INLET CONTROL SERVO MOTOR (See INSTALLATION ) 2. INSTALL BLOWER ASSEMBLY a. Install the blower (see INSTALLATION ). AIR OUTLET CONTROL SERVO MOTOR (FOR AUTOMATIC AIR CONDITIONING SYSTEM) COMPONENTS Fig. 245: Identifying Air Outlet Control Servo Motor Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. REMOVE AIR CONDITIONING UNIT a. Remove the air conditioning radiator (see REMOVAL ). 2. REMOVE AIR OUTLET CONTROL SERVO MOTOR (See DISASSEMBLY ) INSPECTION 1. INSPECT AIR OUTLET CONTROL SERVO MOTOR a. Inspect the servo motor operation. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 210 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 246: Inspecting Air Outlet Control Servo Motor Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Connect the positive (+) lead from the battery to terminal 4 and negative (-) lead to terminal 5, and then check that the lever turns to the "FACE" position smoothly. 2. Connect the positive (+) lead from the battery to terminal 5 and negative (-) lead to terminal 4, and then check that the lever turns to the "DEF" position smoothly. If the operation is not as specified, replace the air outlet control servo motor. Fig. 247: Identifying Air Outlet Control Servo Motor Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION 1. INSTALL AIR OUTLET CONTROL SERVO MOTOR (See INSTALLATION ) 2. INSTALL AIR CONDITIONING UNIT a. Install the air conditioning radiator (see INSTALLATION ). AIR MIX CONTROL SERVO MOTOR (FOR AUTOMATIC AIR CONDITIONING SYSTEM) COMPONENTS Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 211 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 248: Identifying Air Mix Control Servo Motor Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. REMOVE AIR CONDITIONING UNIT a. Remove the air conditioning radiator (see REMOVAL ). 2. REMOVE AIR MIX CONTROL SERVO MOTOR (See DISASSEMBLY ) INSPECTION 1. INSPECT AIR MIX CONTROL SERVO MOTOR a. Inspect the servo motor operation. Fig. 249: Inspecting Air Mix Control Servo Motor Operation (For Automatic Air Conditioning System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Connect the positive (+) lead from the battery to terminal 4 and negative (-) lead to terminal 5, and then check that the lever turns to the "MAX HOT" position smoothly. 2. Connect the positive (+) lead from the battery to terminal 5 and negative (-) lead to terminal 4, and then check that the lever turns to the "MAX COOL" position smoothly. If the operation is not as specified, replace the air mix control servo motor. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 212 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 250: Identifying Air Mix Control Servo Motor Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION 1. INSTALL AIR MIX CONTROL SERVO MOTOR (See INSTALLATION ) 2. INSTALL AIR CONDITIONING UNIT a. Install the air conditioning radiator (see INSTALLATION ). COMPRESSOR AND PULLEY (FOR 2AZ-FE) COMPONENTS Fig. 251: Identifying Compressor And Pulley Components With Torque Specifications (For 2AZ-FE) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See REPLACEMENT ) 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 3. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE a. Remove the bolt and disconnect the cooler refrigerant suction hose from the cooler compressor. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 213 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 b. Remove the O-ring from the cooler refrigerant suction hose. NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them. Fig. 252: Locating Cooler Refrigerant Suction Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE a. Remove the bolt and disconnect the cooler refrigerant discharge hose from the cooler compressor. b. Remove the O-ring from the cooler refrigerant discharge hose. NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them. Fig. 253: Locating Cooler Refrigerant Discharge Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE NO. 1 ENGINE UNDER COVER 6. REMOVE FAN AND GENERATOR V BELT (See REMOVAL ) 7. REMOVE COOLER COMPRESSOR ASSEMBLY a. Disconnect the connector. b. w/o Stud Bolt: Remove the 4 bolts and cooler compressor. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 214 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 c. w/ Stud Bolt: Remove the 3 bolts, nut and cooler compressor. Fig. 254: Removing Cooler Compressor Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION 1. ADJUST COMPRESSOR OIL a. When replacing the compressor and magnetic clutch with a new one, gradually discharge the refrigerant gas from the service valve, and drain the following amount of oil from the new compressor and magnetic clutch before installation. Standard: (Oil capacity inside the new compressor and magnetic clutch: 130 + 15 cc (4.6 + 0.51 fl.oz.)) (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed from the new compressor when replacing) NOTE:     When checking the compressor oil level, observe the precautions on the cooler removal/installation. If a new compressor and magnetic clutch is installed without removing some oil remaining in the pipes of the vehicle, the oil amount will be too large. This prevents heat exchange in the refrigerant cycle and causes refrigerant failure. If the volume of oil remaining in the removed compressor and magnetic clutch is too small, check for oil leakage. Be sure to use ND-OIL 8 or equivalent for compressor oil. 2. INSTALL COOLER COMPRESSOR ASSEMBLY a. w/o Stud Bolt: Install the cooler compressor with the 4 bolts. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 215 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf) NOTE: Tighten the bolts in the order shown in the illustration to install the cooler compressor. b. w/Stud Bolt: Install the cooler compressor with the 3 bolts and nut. Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf) NOTE: Tighten the bolts in the order shown in the illustration to install the cooler compressor. Fig. 255: Installing Cooler Compressor Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Connect the connector. 3. INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE a. Remove the attached vinyl tape from the hose. b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor. Compressor oil: ND-OIL 8 or equivalent c. Install the O-ring on the cooler refrigerant discharge hose. d. Install the cooler refrigerant discharge hose on the cooler compressor with the bolt. Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf) Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 216 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 256: Locating Cooler Refrigerant Discharge Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE a. Remove the attached vinyl tape from the hose. b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor. Compressor oil: ND-OIL 8 or equivalent c. Install the O-ring on the cooler refrigerant suction hose. d. Install the cooler refrigerant suction hose on the cooler compressor with the bolt. Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf) Fig. 257: Locating Cooler Refrigerant Suction Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. 6. 7. 8. 9. INSTALL FAN AND GENERATOR V BELT (See INSTALLATION ) INSTALL NO. 1 ENGINE UNDER COVER CONNECT CABLE TO NEGATIVE BATTERY TERMINAL CHARGE REFRIGERANT (See REPLACEMENT ) WARM UP ENGINE (See REPLACEMENT ) Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 217 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 10. INSPECT FOR REFRIGERANT LEAK (See REPLACEMENT ) COMPRESSOR AND PULLEY (FOR 2GR-FE) COMPONENTS Fig. 258: Identifying Compressor And Pulley Components (For 2GR-FE) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See REPLACEMENT ) 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 3. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE a. Remove the bolt and disconnect the cooler refrigerant suction hose from the cooler compressor. b. Remove the O-ring from the cooler refrigerant suction hose. NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 218 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 259: Locating Cooler Refrigerant Suction Hose And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE a. Remove the bolt and disconnect the cooler refrigerant discharge hose from the cooler compressor. b. Remove the O-ring from the cooler refrigerant discharge hose. NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them. Fig. 260: Locating Cooler Refrigerant Discharge Hose And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE FAN AND GENERATOR V BELT (See REMOVAL ) 6. REMOVE COOLER COMPRESSOR ASSEMBLY a. Disconnect the connector. b. Remove the 4 bolts and cooler compressor. Fig. 261: Identifying Cooler Compressor Assembly And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION 1. INSTALL COOLER COMPRESSOR ASSEMBLY a. Install the cooler compressor with the 4 bolts. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 219 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf) NOTE: Tighten the bolts in the order shown in the illustration to install the cooler compressor. b. Connect the connector. Fig. 262: Identifying Cooler Compressor Assembly And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE a. Remove the attached vinyl tape from the hose. b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor. Compressor oil: ND-OIL 8 or equivalent c. Install the O-ring to the cooler refrigerant discharge hose. d. Connect the cooler refrigerant discharge hose to the cooler compressor with the bolt. Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf) Fig. 263: Locating Cooler Refrigerant Discharge Hose And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 220 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 3. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE a. Remove the attached vinyl tape from the hose. b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor. Compressor oil: ND-OIL 8 or equivalent c. Install the O-ring to the cooler refrigerant suction hose. d. Connect the cooler refrigerant suction hose to the cooler compressor with the bolt. Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf) Fig. 264: Locating Cooler Refrigerant Suction Hose And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. 5. 6. 7. 8. INSTALL FAN AND GENERATOR V BELT (See REMOVAL ) CONNECT CABLE TO NEGATIVE BATTERY TERMINAL CHARGE REFRIGERANT (See REPLACEMENT ) WARM UP ENGINE (See REPLACEMENT ) INSPECT FOR REFRIGERANT LEAK (See REPLACEMENT ) CONDENSER COMPONENTS Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 221 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 265: Identifying Condenser Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Fig. 266: Identifying Condenser Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION 1. INSPECT COOLER CONDENSER ASSEMBLY a. If the fins of the cooler condenser are dirty, clean them with water. Dry the fins with compressed air. NOTE: Do not damage the fins of the condenser. b. If a fin of the cooler condenser is bent, straighten it using a screwdriver or pliers. 2. CHECK CONDENSER FOR LEAKAGE OF REFRIGERANT a. Using a halogen leak detector, check the pipe joints for gas leakage. b. If gas leakage is detected in a joint, check the torque of the joint. REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See REPLACEMENT ) 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 222 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 3. REMOVE FRONT BUMPER COVER a. Remove front bumper cover (see REMOVAL ). 4. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE a. Remove the bolt and disconnect the cooler refrigerant discharge hose from the cooler condenser. b. Remove the O-ring from the cooler refrigerant discharge hose. NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them. Fig. 267: Locating Cooler Refrigerant Discharge Hose And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. DISCONNECT COOLER REFRIGERANT LIQUID PIPE a. Remove the bolt and disconnect the cooler refrigerant liquid pipe from the cooler condenser. b. Remove the O-ring from the cooler refrigerant liquid pipe. NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them. Fig. 268: Locating Cooler Refrigerant Liquid Pipe And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 223 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 6. REMOVE RADIATOR SUPPORT UPPER BRACKET a. Remove the 2 bolts and 2 brackets. Fig. 269: Identifying Radiator Support Upper Bracket And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE NO. 2 FAN SHROUD a. Remove the 2 bolts and fan shroud. Fig. 270: Identifying Fan Shroud And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE COOLER CONDENSER ASSEMBLY a. Remove the cooler condenser. Fig. 271: Removing Cooler Condenser Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 224 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 9. REMOVE COOLER DRYER a. Using a 14 mm socket hexagon wrench, remove the cap from the modulator. Fig. 272: Installing Cap To Modulator Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the O-ring from the cap. Fig. 273: Locating O-Ring From Cap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using pliers, remove the cooler dryer. Fig. 274: Installing Cooler Dryer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION Microsoft Tuesday, August 18, 2009 3:53:57 PM Page 225 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 1. INSTALL COOLER DRYER a. Using pliers, install the cooler dryer. Fig. 275: Installing Cooler Dryer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Apply a sufficient amount of compressor oil to the contact surfaces of a new O-ring and the cap. Compressor oil: ND-OIL 8 or equivalent c. Install the O-ring to the cap. Fig. 276: Locating O-Ring To Cap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using a 14 mm socket hexagon wrench, install the cap to the modulator. Torque: 2.9 N*m (29 kgf*cm, 25 in.*lbf) Microsoft Tuesday, August 18, 2009 3:53:58 PM Page 226 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 277: Installing Cap To Modulator Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL COOLER CONDENSER ASSEMBLY a. Install the cooler condenser. Fig. 278: Locating Cooler Condenser Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL NO. 2 FAN SHROUD a. Install the fan shroud with the 2 bolts. Torque: 10.5 N*m (107 kgf*cm, 8 ft.*lbf) Fig. 279: Identifying Fan Shroud And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. INSTALL RADIATOR SUPPORT UPPER BRACKET Microsoft Tuesday, August 18, 2009 3:53:58 PM Page 227 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 a. Install the 2 brackets with the 2 bolts. Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf) HINT: If the condenser is replaced with a new one, add compressor oil to the new condenser. Capacity: 40 cc (1.4 fl. oz.) Compressor oil: ND-8 or equivalent Fig. 280: Identifying Radiator Support Upper Bracket And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. INSTALL COOLER REFRIGERANT LIQUID PIPE a. Remove the attached vinyl tape from the pipe and the connecting part of the cooler condenser. b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the pipe joint. Compressor oil: ND-OIL 8 or equivalent c. Install the O-ring on the cooler refrigerant liquid pipe. d. Install the cooler refrigerant liquid pipe on the cooler condenser with the bolt. Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf) Microsoft Tuesday, August 18, 2009 3:53:58 PM Page 228 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 281: Locating Cooler Refrigerant Liquid Pipe And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE a. Remove the attached vinyl tape from the hose and the connecting part of the cooler condenser. b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the hose joint. Compressor oil: ND-OIL 8 or equivalent c. Install the O-ring on the cooler refrigerant discharge hose. d. Install the cooler refrigerant discharge hose on the cooler condenser with the bolt. Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf) Fig. 282: Locating Cooler Refrigerant Discharge Hose And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. ADJUST HOOD SUB-ASSEMBLY (See ADJUSTMENT ) 8. INSTALL FRONT BUMPER COVER a. Install the front bumper cover (see INSTALLATION ). 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 10. CHARGE REFRIGERANT (See REPLACEMENT ) 11. WARM UP ENGINE (See REPLACEMENT ) Microsoft Tuesday, August 18, 2009 3:53:58 PM Page 229 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 12. INSPECT FOR REFRIGERANT LEAK (See REPLACEMENT ) ROOM TEMPERATURE SENSOR (FOR AUTOMATIC AIR CONDITIONING SYSTEM) COMPONENTS Fig. 283: Identifying Room Temperature Sensor Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. REMOVE LOWER INSTRUMENT PANEL a. Remove the lower instrument panel (see REMOVAL ). 2. REMOVE ROOM TEMPERATURE SENSOR a. Disconnect the duct. b. Disconnect the connector. c. Detach the claws and remove the sensor. Fig. 284: Locating Room Temperature Sensor Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. INSPECT ROOM TEMPERATURE SENSOR Microsoft Tuesday, August 18, 2009 3:53:58 PM Page 230 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 a. Measure the resistance of the sensor. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 1-2 10°C (50°F) 3.00 to 3.73 kohms 1-2 15°C (59°F) 2.45 to 2.88 kohms 1-2 20°C (68°F) 1.95 to 2.30 kohms 1-2 25°C (77°F) 1.60 to 1.80 kohms 1-2 30°C (86°F) 1.28 to 1.47 kohms 1-2 35°C (95°F) 1.00 to 1.22 kohms 1-2 40°C (104°F) 0.80 to 1.00 kohms 1-2 45°C (113°F) 0.65 to 0.85 kohms 1-2 50°C (122°F) 0.50 to 0.70 kohms 1-2 55°C (131°F) 0.44 to 0.60 kohms 1-2 60°C (140°F) 0.36 to 0.50 kohms NOTE:   Touching the sensor even slightly may change the resistance value. Hold the connector of the sensor. When measuring the resistance, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph ). If the result is not as specified, replace the room temperature sensor. Fig. 285: Identifying Room Temperature Sensor Resistance Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION Microsoft Tuesday, August 18, 2009 3:53:58 PM Page 231 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 1. INSTALL ROOM TEMPERATURE SENSOR a. Attach the claws to install the sensor. b. Connect the connector. c. Connect the duct. 2. INSTALL LOWER INSTRUMENT PANEL a. Install the lower instrument panel (see INSTALLATION ). AMBIENT TEMPERATURE SENSOR (FOR AUTOMATIC AIR CONDITIONING SYSTEM) COMPONENTS Fig. 286: Identifying Ambient Temperature Sensor Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT BUMPER COVER a. Remove the front bumper cover (see REMOVAL ). 3. REMOVE AMBIENT TEMPERATURE SENSOR a. Using a screwdriver, pull out the sensor, then disconnect the connector. HINT: Tape the screwdriver tip before use. INSPECTION Microsoft Tuesday, August 18, 2009 3:53:58 PM Page 232 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 1. INSPECT AMBIENT TEMPERATURE SENSOR a. Measure the resistance of the sensor. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 1-2 10°C (50°F) 3.00 to 3.73 kohms 1-2 15°C (59°F) 2.45 to 2.88 kohms 1-2 20°C (68°F) 1.95 to 2.30 kohms 1-2 25°C (77°F) 1.60 to 1.80 kohms 1-2 30°C (86°F) 1.28 to 1.47 kohms 1-2 35°C (95°F) 1.00 to 1.22 kohms 1-2 40°C (104°F) 0.80 to 1.00 kohms 1-2 45°C (113°F) 0.65 to 0.85 kohms 1-2 50°C (122°F) 0.50 to 0.70 kohms 1-2 55°C (131°F) 0.44 to 0.60 kohms 1-2 60°C (140°F) 0.36 to 0.50 kohms NOTE:   Touching the sensor even slightly may change the resistance value. Hold the connector of the sensor. When measuring the resistance, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph ). If the result is not as specified, replace the ambient temperature sensor. Fig. 287: Identifying Ambient Temperature Sensor Resistance Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Microsoft Tuesday, August 18, 2009 3:53:58 PM Page 233 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 INSTALLATION 1. INSTALL AMBIENT TEMPERATURE SENSOR a. Connect the connector, and then push in the sensor. 2. INSTALL FRONT BUMPER COVER a. Install the front bumper cover (see INSTALLATION ). 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. CHECK SRS WARNING LIGHT a. Check SRS warning light (see DIAGNOSIS SYSTEM ). EVAPORATOR TEMPERATURE SENSOR REMOVAL 1. REMOVE AIR CONDITIONING UNIT a. Remove the air conditioning radiator (see REMOVAL ). 2. REMOVE EVAPORATOR TEMPERATURE SENSOR (See DISASSEMBLY ) INSPECTION 1. INSPECT EVAPORATOR TEMPERATURE SENSOR a. Measure the resistance of the sensor. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 1-2 -10°C (14°F) 7.30 to 9.10 kohms 1-2 -5°C (23°F) 5.65 to 6.95 kohms 1-2 0°C (32°F) 4.40 to 5.35 kohms 1-2 5°C (41°F) 3.40 to 4.15 kohms 1-2 10°C (50°F) 2.70 to 3.25 kohms 1-2 15°C (59°F) 2.14 to 2.58 kohms 1-2 20°C (68°F) 1.71 to 2.05 kohms 1-2 25°C (77°F) 1.38 to 1.64 kohms 1-2 30°C (86°F) 1.11 to 1.32 kohms NOTE:   Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. When measuring, the sensor temperature must be almost the same as the ambient temperature. Microsoft Tuesday, August 18, 2009 3:53:58 PM Page 234 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 288: Identifying Evaporator Temperature Sensor Resistance Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: As the temperature increases, the resistance decreases (see the graph ). If the result is not as specified, replace the sensor. INSTALLATION 1. INSTALL EVAPORATOR TEMPERATURE SENSOR (See DISASSEMBLY ) 2. INSTALL AIR CONDITIONING UNIT a. Install the air conditioning unit (see INSTALLATION ). SOLAR SENSOR (FOR AUTOMATIC AIR CONDITIONING SYSTEM) COMPONENTS Fig. 289: Identifying Solar Sensor (For Automatic Air Conditioning System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Microsoft Tuesday, August 18, 2009 3:53:58 PM Page 235 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE SOLAR SENSOR a. Using a screwdriver, pull out the solar sensor, then disconnect the connector. HINT: Tape the screwdriver tip before use. Fig. 290: Locating Solar Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. INSPECT SOLAR SENSOR a. Using an ohmmeter, connect the positive lead to terminal 2 and the negative lead to terminal 1, then measure the resistance between the terminals. Standard resistance RESISTANCE SPECIFICATION Tester Connection Connection Specified Condition 1-2 Sensor subject to electric light Except infinity ohms 1-2 Sensor covered with a cloth infinity ohms Microsoft Tuesday, August 18, 2009 3:53:58 PM Page 236 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 291: Identifying Solar Sensor Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: The connection procedure for using a digital tester such as a TOYOTA electrical tester is shown above. When using an analog tester, connect the positive (+) lead to terminal 1 and the negative (-) lead to terminal 2 of the A/C solar sensor. HINT:   As the inspection light is moved away from the sensor, the voltage increases. Use an incandescent lamp for inspection. Bring it within 30 cm (11.8 in.) of the A/C solar sensor. If the result is not as specified, replace the solar sensor. INSTALLATION 1. INSTALL SOLAR SENSOR a. Connect the connector, and then push in the solar sensor. 2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 3. CHECK SRS WARNING LIGHT a. Check the SRS warning light (see DIAGNOSIS SYSTEM ). AIR CONDITIONING PRESSURE SENSOR ON-VEHICLE INSPECTION 1. CHECK PRESSURE SENSOR a. Check the wire harness. 1. Disconnect the connector of the pressure sensor. 2. Measure the resistance of the wire harness side connector. Microsoft Tuesday, August 18, 2009 3:53:58 PM Page 237 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 292: Identifying Pressure Sensor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition 1 - Body ground Below 1 ohms 3. Turn the ignition switch ON. 4. Measure the voltage of the wire harness side connector. Standard voltage VOLTAGE SPECIFICATION Tester Connection Specified Condition 1-3 4.7 to 5,3 V If the result is not as specified, replace the pressure sensor. b. Check the pressure sensor. 1. Set the manifold gauge. 2. Connect the connector to the pressure sensor. 3. Warm up the engine. 4. Switch the A/C ON. 5. Measure the voltage. Standard voltage VOLTAGE SPECIFICATION Tester Connection Refrigerant Pressure Specified Condition for Automatic Air Conditioner: E37-9 (PRE) - E37-13 (SG-2) 0.176 to 3.025 MPa (1.8 to 30.9 kgf/cm2 ) 0.76 to 4.74 V Microsoft Tuesday, August 18, 2009 3:53:58 PM Page 238 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 for Manual Air Conditioner: E36-12 (PRE) 0.176 to 3.025 MPa (1.8 to - E36-10 (SG-2) 30.9 kgf/cm2 ) 0.76 to 4.74 V If the result is not as specified, replace the pressure sensor. Fig. 293: Identifying Voltage Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEATER RELAY ON-VEHICLE INSPECTION 1. INSPECT RELAY (Marking: HTR) a. Measure the resistance of the HTR relay. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition 3-4 Below 1 ohms 3-5 10 kohms or higher 3-5 Below 1 ohms (when battery voltage is applied to terminals 1 and 2) Fig. 294: Identifying Heater Blower Motor Relay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the result is not as specified, replace the relay. Microsoft Tuesday, August 18, 2009 3:53:58 PM Page 239 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 AIR CONDITIONING PANEL (FOR AUTOMATIC AIR CONDITIONING SYSTEM) COMPONENTS Fig. 295: Identifying Air Conditioning Control Assembly (For Automatic Air Conditioning System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE: 2. 3. 4. 5. Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL CENTER (See REMOVAL ) REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL CENTER (See REMOVAL ) REMOVE RADIO RECEIVER (See REMOVAL ) REMOVE AIR CONDITIONING CONTROL ASSEMBLY a. Remove the 2 screws. b. Using a screwdriver, detach the 3 clips. HINT: Tape the screwdriver tip before use. c. Connect the connectors and remove the air conditioning control. Microsoft Tuesday, August 18, 2009 3:53:58 PM Page 240 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 296: Identifying Air Conditioning Control Assembly And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION 1. INSTALL AIR CONDITIONING CONTROL ASSEMBLY a. Connect the connectors. b. Attach the 3 clips to install the air conditioning control. Fig. 297: Identifying Air Conditioning Control Assembly And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. 3. 4. 5. 6. c. Install the 2 screws. INSTALL RADIO RECEIVER (See INSTALLATION ) INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL CENTER (See INSTALLATION ) INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL CENTER (See INSTALLATION ) CONNECT CABLE TO NEGATIVE BATTERY TERMINAL CHECK SRS WARNING LIGHT a. Check the SRS warning light (see DIAGNOSIS SYSTEM ). AIR CONDITIONING PANEL (FOR MANUAL AIR CONDITIONING SYSTEM) COMPONENTS Microsoft Tuesday, August 18, 2009 3:53:58 PM Page 241 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 298: Identifying Air Conditioning Control Assembly Components (For Manual Air Conditioning System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE: 2. 3. 4. 5. Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL CENTER (See REMOVAL ) REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL CENTER (See REMOVAL ) REMOVE RADIO RECEIVER ASSEMBLY (See REMOVAL ) REMOVE AIR CONDITIONING CONTROL ASSEMBLY a. Remove the 2 screws. b. Using a screwdriver, detach the 3 clips. HINT: Tape the screwdriver tip before use. c. Disconnect the connectors and remove the air conditioning control. Fig. 299: Identifying Air Conditioning Control Assembly And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Microsoft Tuesday, August 18, 2009 3:53:58 PM Page 242 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 6. REMOVE AIR MIX CONTROL SWITCH a. Detach the 2 claws and remove the air mix control switch. Fig. 300: Removing Air Mix Control Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE BLOWER CONTROL SWITCH a. Detach the 2 claws and remove the blower control switch. Fig. 301: Removing Blower Control Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE AIR VENT MODE CONTROL SWITCH a. Detach the 2 claws and remove the mode control switch. Fig. 302: Removing Air Vent Mode Control Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION Microsoft Tuesday, August 18, 2009 3:53:58 PM Page 243 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 1. INSTALL AIR VENT MODE CONTROL SWITCH a. Attach the 2 claws to install the mode control switch. 2. INSTALL BLOWER CONTROL SWITCH a. Attach the 2 claws to install the blower control switch. 3. INSTALL AIR MIX CONTROL SWITCH a. Attach the 2 claws to install the air mix control switch. 4. INSTALL AIR CONDITIONING CONTROL ASSEMBLY a. Connect the connectors. b. Attach the 3 clips to install the air conditioning control. c. Install the 2 screws. Fig. 303: Identifying Air Conditioning Control Assembly And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. 6. 7. 8. 9. INSTALL RADIO RECEIVER ASSEMBLY (w/ Radio Receiver) (See INSTALLATION ) INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL CENTER (See INSTALLATION ) INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL CENTER (See INSTALLATION ) CONNECT CABLE TO NEGATIVE BATTERY TERMINAL CHECK SRS WARNING LIGHT a. Check the SRS warning light (see DIAGNOSIS SYSTEM ). AIR CONDITIONING AMPLIFIER COMPONENTS Microsoft Tuesday, August 18, 2009 3:53:58 PM Page 244 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 304: Identifying Air Conditioning Amplifier Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY a. Detach the clamp. b. Disconnect the connector. c. Remove the screw and A/C amplifier. Fig. 305: Identifying Air Conditioning Amplifier Assembly Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION 1. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY a. Install the A/C amplifier with the screw. b. Connect the connector. c. Attach the clamp. Microsoft Tuesday, August 18, 2009 3:53:58 PM Page 245 © 2005 Mitchell Repair Information Company, LLC. 2008 Toyota RAV4 2008 HVAC Air Conditioning - RAV4 Fig. 306: Identifying Air Conditioning Amplifier Assembly Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Microsoft Tuesday, August 18, 2009 3:53:58 PM Page 246 © 2005 Mitchell Repair Information Company, LLC.