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

Warnings

Tools required

Parts

• AC Condenser × 1 — Use OEM specification
• AC line O-rings (high and low side) × 4 — Use OEM specification
• AC refrigerant (R-1234yf or R-134a) × 1 — Check vehicle label under hood
• PAG oil for AC system × 1 — ND-11 or equivalent
• Radiator support seal/cushions (if damaged) × 1 — Use OEM specification

Preparation

1. Verify the exact refrigerant type (R-134a or R-1234yf) from the underhood AC specification label
2. Park vehicle on level surface and apply parking brake
3. Allow engine to cool completely if recently operated
4. Disconnect negative battery terminal and wait 2 minutes for airbag system to discharge
5. Raise front of vehicle and support securely on jack stands
6. Remove engine under cover/splash shield if equipped

Procedure

1. 1

   Recover AC refrigerant
   Connect AC recovery machine to service ports. Follow machine instructions to completely recover all refrigerant from the system. Record the amount recovered for recharge reference. Ensure system pressure reaches 0 psi/vacuum before proceeding.
   ⚠️Use only certified recovery equipment appropriate for the refrigerant type in your vehicle (R-134a or R-1234yf equipment is NOT interchangeable)
2. 2

   Remove front bumper cover
   Remove screws securing upper bumper cover to radiator support. Remove fasteners at wheel well liners on both sides. Remove lower bumper screws/clips. Disconnect fog light connectors if equipped. Carefully pull bumper cover forward and away from vehicle. Set aside in safe location to prevent damage.
3. 3

   Remove radiator grille and upper support panels
   Remove the radiator grille by releasing clips and removing mounting fasteners. Remove the upper radiator support covers and any plastic panels blocking access to condenser mounting area. Note the position of all clips and fasteners for reassembly.
4. 4

   Disconnect AC lines from condenser
   Locate the high-side and low-side AC line connections at the condenser (passenger side of condenser). Using appropriate AC line disconnect tools, separate the line fittings from the condenser. Cap or plug all open connections immediately to prevent contamination and moisture entry. Discard old O-rings.
   ⚠Some residual refrigerant pressure may remain even after recovery. Have rags ready to catch any oil discharge
5. 5

   Remove hood latch assembly (if necessary)
   On some model years, the hood latch assembly may need to be loosened or removed for condenser clearance. Mark the position of the latch for realignment. Remove mounting bolts and carefully move assembly aside, supporting the latch cable.
6. 6

   Remove condenser mounting bolts
   Locate the condenser mounting brackets at the top and bottom of the condenser. The condenser mounts to the radiator support with multiple bolts. Remove these mounting bolts while supporting the condenser. The condenser sits in front of the radiator and is held by brackets at the upper corners and lower mounts.
   ⚠Support condenser while removing final bolts to prevent it from falling and damaging radiator
   Torque spec

   Condenser Mounting Bolts12 Nm (9 lb-ft)
7. 7

   Remove condenser from vehicle
   Carefully tilt and maneuver the condenser upward and forward out of the engine bay. Take care not to damage the radiator fins or cooling fan. Inspect the radiator support cushions/seals and replace if damaged. Drain any residual oil from old condenser and measure quantity.
8. 8

   Prepare new condenser
   Remove new condenser from packaging. Add the appropriate amount of fresh ND-11 PAG oil to the new condenser (typically same amount drained from old unit, or 1-2 oz if none was recovered). Install new O-rings on condenser ports, lightly coating them with PAG oil. Do not overtighten caps if condenser comes with protective caps.
   ℹ️New condensers may come pre-charged with oil. Check manufacturer instructions and adjust oil quantity accordingly to avoid overcharging system
9. 9

   Install new condenser
   Carefully guide the new condenser into position in front of the radiator, routing it between the radiator and support structure. Align mounting holes with brackets. Ensure condenser is properly seated on lower mounts and rubber cushions are in place.
10. 10

    Install condenser mounting bolts
    Install condenser mounting bolts through brackets and tighten to specification. Start all bolts by hand before torquing. Verify condenser is secure and properly aligned with no contact points that could cause vibration.
    Torque spec

    Condenser Mounting Bolts12 Nm (9 lb-ft)
11. 11

    Connect AC lines to condenser
    Remove caps/plugs from condenser ports and AC lines. Install new O-rings on line fittings, lubricating with fresh PAG oil. Connect high-side and low-side lines to condenser ports, ensuring proper alignment. Torque line fittings to specification using a flare nut wrench or appropriate tool.
    Torque spec

    AC Line Fittings20 Nm (15 lb-ft)
12. 12

    Reinstall hood latch and support components
    If hood latch was removed or loosened, reinstall it to its marked position and secure mounting bolts. Verify latch operation and alignment. Reinstall upper radiator support covers, grille, and any plastic panels removed earlier.
13. 13

    Reinstall front bumper cover
    Reconnect fog light connectors if equipped. Position bumper cover and align with mounting points. Install all fasteners, clips, and screws. Ensure even gaps and proper alignment on both sides. Verify all clips are fully seated.
14. 14

    Vacuum and recharge AC system
    Connect vacuum pump to AC service ports and evacuate system to at least 29 inches Hg for minimum 30-45 minutes. Monitor vacuum gauge for 10 minutes after pump shutoff to verify system holds vacuum (no leaks). If vacuum holds, recharge system with exact refrigerant amount specified on underhood label using proper refrigerant and recovery/recharge equipment.
    ⚠If system does not hold vacuum, there is a leak. Do not charge with refrigerant until leak is found and repaired
15. 15

    Final checks and testing
    Reinstall engine under cover. Reconnect battery negative terminal. Start engine and turn AC to maximum cold with fan on high. Allow system to run for 5-10 minutes. Check for proper cooling, verify compressor engages, and inspect all connections for leaks using electronic leak detector or soap solution. Monitor system pressures with gauges to verify proper operation.

Reassembly

1. Ensure all AC line connections are tight and properly torqued to prevent leaks
2. Verify hood latch alignment and operation before closing hood fully
3. Confirm bumper cover alignment and all clips are engaged properly
4. Double-check that no tools or fasteners were left in engine compartment

Verification

• Verify AC system produces cold air within 2-3 minutes of startup
• Check that center vent temperature reaches 40-50°F with ambient temperature around 75-80°F
• Confirm compressor clutch engages when AC is turned on
• Inspect all AC line connections for oil residue or refrigerant leaks using leak detector
• Verify system high and low side pressures are within normal operating range (typically 200-250 psi high side, 25-35 psi low side at idle with 75-80°F ambient)
• Confirm no abnormal noises from AC system during operation
• Test drive vehicle and verify AC performance under various conditions

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