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

Warnings

Tools required

Parts

• AC hose assembly (specify which hose: suction, discharge, or liquid line) × 1 — Use OEM specification
• AC O-ring kit × 1 — Use OEM specification
• R-134a or R-1234yf refrigerant × 1 — Check underhood label for refrigerant type
• PAG oil (viscosity matched to system) × 1 — ND-11 or equivalent

Preparation

1. Verify which refrigerant type (R-134a or R-1234yf) is used by checking the underhood AC specification label
2. Park vehicle on level surface and engage parking brake
3. Allow engine to cool completely if recently operated
4. Disconnect negative battery terminal and wait 90 seconds for airbag system discharge
5. Identify which AC hose assembly requires replacement (suction line, discharge line, or liquid line)
6. Ensure AC recovery machine is certified for the refrigerant type in this vehicle

Procedure

1. 1

   Recover refrigerant from AC system
   Connect AC recovery machine to service ports following manufacturer instructions. The low-pressure port is on the larger suction line, high-pressure port is on the smaller discharge line. Run recovery machine until system is fully evacuated and refrigerant tank shows complete recovery. Record amount of refrigerant recovered for recharge reference.
   ⚠️Only use certified recovery equipment. Never vent refrigerant to atmosphere.
2. 2

   Remove engine cover if equipped
   If your RAV4 has a plastic engine cover, pull upward firmly to disengage the retaining clips. Set cover aside in a clean area.
3. 3

   Access AC line routing area
   Depending on which hose is being replaced, you may need to remove the air intake duct or battery for better access. For suction and liquid lines, remove the air intake duct by loosening clamps and disconnecting from air filter housing. For discharge line access near compressor, you may need to remove the plastic undertray if working from below.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
4. 4

   Disconnect electrical connectors if applicable
   If replacing the discharge line near the compressor, disconnect the AC pressure sensor electrical connector by pressing the release tab and pulling straight off. Note connector orientation for reinstallation.
5. 5

   Remove AC line mounting brackets
   Remove any mounting bracket bolts securing the AC hose assembly to the chassis, engine, or radiator support. Typically 10mm bolts. Keep track of bracket positions and hardware for reassembly.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
6. 6

   Disconnect AC line fittings
   Using flare nut wrenches to prevent rounding, carefully loosen and remove the AC line fittings at both ends of the hose assembly. For lines connecting to the compressor, evaporator, or condenser, support the component being disconnected from to prevent stress. Remove and discard all old O-rings from fittings.
   ⚠Use flare nut wrenches to prevent damage to soft aluminum fittings. Do not use standard open-end wrenches.
7. 7

   Remove AC hose assembly
   Carefully route the old AC hose assembly out of the engine bay, noting the exact routing path, clip locations, and any protective grommets or insulators. Take photos if necessary to aid reinstallation. Inspect the old hose for failure point to prevent recurrence.
8. 8

   Prepare new AC hose assembly
   Unpack new AC hose assembly and verify it matches the old unit in length, fitting types, and routing configuration. Install new O-rings on all fittings (provided in O-ring kit). Lightly coat new O-rings with clean PAG oil appropriate for your system (ND-11 or equivalent). Add the amount of PAG oil specified for the hose being replaced (typically 10-20ml depending on hose).
   ⚠Use only fresh PAG oil compatible with your refrigerant type. R-1234yf systems may require POE oil instead.
9. 9

   Install new AC hose assembly
   Route the new AC hose assembly through the engine bay following the exact path of the original. Ensure the hose does not contact sharp edges, moving components, or hot exhaust parts. Install any protective grommets or insulators in their original positions. Do not fully tighten fittings yet.
   ⚠Verify hose routing allows clearance from belts, pulleys, and exhaust components during all engine movement.
10. 10

    Install AC line fittings
    Hand-thread both AC line fittings to ensure proper engagement and prevent cross-threading. Once hand-tight, use flare nut wrenches to tighten fittings to specification. Torque evenly and do not over-tighten aluminum fittings.
    Torque spec

    AC Line Fittings20 Nm (15 lb-ft)
11. 11

    Reinstall mounting brackets
    Reinstall all AC line mounting brackets in their original positions. Ensure hose is properly seated in bracket clips before tightening bolts. Torque mounting bolts to specification.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
12. 12

    Reconnect electrical components
    If AC pressure sensor or other electrical connectors were disconnected, reconnect them ensuring a positive click. Reinstall air intake duct, battery, or any other components removed for access, tightening hose clamps to specification.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
13. 13

    Evacuate AC system
    Connect vacuum pump to AC service ports. Evacuate system to at least 29 inches of mercury (500 microns is preferable). Maintain vacuum for minimum 30 minutes, ideally 45-60 minutes. Monitor for vacuum decay which would indicate a leak.
    ⚠Proper evacuation removes moisture that can damage AC components and freeze at expansion valve.
14. 14

    Recharge AC system
    Using AC manifold gauges and charging equipment, recharge system with the amount of refrigerant recorded during recovery (or factory specification if significantly different). Add refrigerant slowly through low-pressure port with engine running and AC on MAX. Monitor pressures and verify proper charge level.
    ⚠Overcharging can damage compressor. Follow factory specifications for refrigerant capacity.
15. 15

    Perform leak test
    With system fully charged, use electronic leak detector or UV dye to check all new fittings and connections for leaks. Pay special attention to newly installed fittings. If UV dye is used, run system for 15 minutes then inspect with UV light.

Reassembly

1. Reinstall engine cover by aligning clips and pressing down until seated
2. Reconnect negative battery terminal
3. Verify all tools and parts have been removed from engine bay
4. Ensure no refrigerant odor is present indicating leaks

Verification

• Start engine and turn AC to MAX cold with fan on high
• Verify AC compressor engages (clutch clicks and pulley spins)
• Check that center dash vents blow cold air within 2-3 minutes (typically 40-50°F/4-10°C)
• Monitor AC pressures: Low side should be 25-40 PSI, high side 200-250 PSI at idle with 80°F ambient temperature
• Listen for unusual noises from compressor or hissing indicating leaks
• Verify AC performance matches pre-repair operation
• Recheck all fittings for leaks after system has cycled several times
• Test AC operation in recirculation and fresh air modes

More procedures for this vehicle