This procedure covers the removal and replacement of the AC compressor on a 2019-2024 Toyota RAV4 with the 2.5L I4 engine, including refrigerant recovery, compressor replacement, and system recharge.

Warnings

Tools required

Parts

• AC Compressor × 1 — Use OEM or equivalent for 2.5L RAV4
• AC line O-rings × 4 — Use OEM specification
• PAG 46 compressor oil × 1 — Toyota ND-11 or equivalent PAG 46
• Serpentine belt × 1 — Replace if worn or contaminated

Fluids

• R-1234yf Refrigerant

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely if recently operated
3. Disconnect negative battery terminal and wait 90 seconds
4. Remove engine cover if equipped
5. Document refrigerant capacity and PAG oil amount from underhood label

Procedure

1. 1

   Recover AC Refrigerant
   Connect AC recovery machine to high and low side service ports. Follow machine instructions to completely recover all refrigerant from the system. Record the amount of oil recovered for reference when refilling. Wait at least 5 minutes after recovery to allow residual pressure to equalize.
2. 2

   Remove Serpentine Belt
   Locate the serpentine belt tensioner on the right side of the engine. Using a 14mm socket or serpentine belt tool, rotate tensioner clockwise to release belt tension. Slide belt off compressor pulley first, then remove from remaining pulleys. Inspect belt for oil contamination from failed compressor; replace if contaminated.
3. 3

   Disconnect Compressor Clutch Connector
   Locate the electrical connector on the front of the compressor clutch. Press the release tab and disconnect the connector. Remove the connector mounting bolt if equipped and secure connector away from work area.
   ℹ️Some connectors use a locking tab that must be lifted before disconnecting
   Torque spec

   Clutch Connector Bolt8 Nm (6 lb-ft)
4. 4

   Disconnect AC Refrigerant Lines
   Locate the suction line (larger diameter) and discharge line (smaller diameter) connections at the rear of the compressor. Use two wrenches to prevent twisting - one to hold the compressor fitting, one to loosen the line nut. Remove both line connections and immediately cap all openings to prevent moisture and contamination entry. Remove and discard all old O-rings.
   ⚠Small amount of residual oil may drain from lines. Have shop towels ready
5. 5

   Remove Compressor Mounting Bolts
   The compressor is secured by three mounting bolts accessible from the front and right side of the engine. Remove the upper bolt (17mm), front lower bolt (17mm), and rear lower bolt (17mm). Support compressor while removing final bolt to prevent dropping.
   ⚠Compressor weighs approximately 12 lbs. Support during removal to avoid strain or damage
6. 6

   Remove Compressor from Vehicle
   Carefully maneuver the compressor out from the engine bay. It may be necessary to tilt and rotate the compressor to clear surrounding components. Drain any remaining oil from old compressor into a graduated container and measure to determine oil balance for new compressor.
7. 7

   Prepare New Compressor
   Remove shipping caps from new compressor ports. Measure and drain the shipping oil from the new compressor. Calculate correct oil amount: add the amount recovered from system plus the amount drained from old compressor, then subtract the amount drained from new compressor. Add the calculated amount of fresh PAG 46 oil to the new compressor through the suction port, rotating the clutch hub by hand 10 times to distribute oil internally.
   ℹ️Typical system capacity is 120-140ml PAG oil. If significantly different, inspect for oil accumulation in other components
8. 8

   Install New Compressor
   Position new compressor in mounting location, aligning mounting holes. Start all three mounting bolts by hand to ensure proper thread engagement. Tighten bolts in a crossing pattern to specification.
9. 9

   Install New O-Rings and Connect Lines
   Coat new O-rings lightly with PAG oil and install into line fittings. Verify O-rings are properly seated in grooves without twisting. Hand-thread line connections onto compressor fittings until snug, then tighten to specification using two-wrench method to prevent twisting the compressor fittings.
   ⚠Over-tightening can damage O-rings or aluminum fittings. Use torque wrench
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
10. 10

    Reconnect Electrical Connector
    Connect the clutch electrical connector to the compressor, ensuring it clicks into place. If equipped with a mounting bolt, install and tighten to specification. Verify connector is fully seated and lock tab is engaged.
    Torque spec

    Clutch Connector Bolt8 Nm (6 lb-ft)
11. 11

    Install Serpentine Belt
    Route new or existing belt around all pulleys except compressor. Verify belt routing matches underhood diagram. Rotate tensioner clockwise and slide belt onto compressor pulley last. Release tensioner slowly and verify belt is centered on all pulleys.
12. 12

    Evacuate and Recharge AC System
    Connect AC machine to service ports. Evacuate system to deep vacuum (29+ inches Hg) for minimum 45 minutes to remove all moisture and air. Perform vacuum hold test for 10 minutes to verify system integrity. If vacuum holds, recharge system with correct amount of R-1234yf refrigerant per underhood label (typically 550-600 grams).
    ⚠If vacuum does not hold, there is a leak that must be repaired before charging

Reassembly

1. Reinstall engine cover if removed
2. Reconnect negative battery terminal
3. Verify no tools or parts remain in engine bay

Verification

• Start engine and turn AC to MAX with blower on high
• Verify compressor clutch engages within 30 seconds
• Check for unusual noise or vibration from compressor during operation
• Verify cold air output from vents (should reach 40-45°F at vents within 5 minutes)
• Inspect all line connections for signs of refrigerant leakage using leak detector
• Check system pressures: Low side should be 25-40 PSI, high side 200-250 PSI at idle with 80°F ambient
• Verify clutch cycles normally when system reaches temperature

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