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

Warnings

Tools required

Parts

• AC high-side hose assembly × 1 — Use OEM specification
• AC line O-rings × 1 — Typically 4 O-rings per hose assembly
• R134a refrigerant × 1 — Approximately 1.3 lbs total system capacity
• PAG 46 compressor oil × 1 — Use Toyota-approved PAG oil

Preparation

1. Park vehicle on level ground and engage parking brake
2. Ensure engine is cold before beginning work
3. Open hood and secure with prop rod
4. Identify the high-side AC hose routing from condenser to compressor (typically silver/aluminum colored line)
5. Connect AC recovery machine to service ports following machine manufacturer instructions
6. Verify AC system contains refrigerant by checking gauge pressures

Procedure

1. 1

   Recover refrigerant from AC system
   Using a certified AC recovery/recycling machine, recover all refrigerant from the system. Connect to both low and high-side service ports. Follow the machine's operating procedure to fully evacuate refrigerant. Record the amount recovered for comparison during recharge. Wait for machine to indicate recovery is complete and system pressure is at atmospheric level.
2. 2

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

   Locate and access high-side AC hose connections
   The high-side hose runs from the condenser (front of engine bay) to the compressor (driver's side of engine). Trace the hose to identify both connection points. You may need to remove or reposition wiring harnesses or plastic covers for access. Note the routing path for reinstallation.
4. 4

   Disconnect high-side hose at condenser
   Using a 14mm or 17mm flare nut wrench (size varies by connection point), carefully loosen the fitting at the condenser. Use a backup wrench on the condenser fitting to prevent twisting the condenser tubes. Once loose, unthread by hand and carefully separate the connection. Cap or plug the condenser port immediately to prevent contamination. Remove and discard the old O-rings.
   ⚠Use flare nut wrenches to prevent rounding off the soft aluminum fittings. Do not use standard open-end wrenches.
5. 5

   Disconnect high-side hose at compressor
   Using the appropriate flare nut wrench, loosen the fitting at the compressor discharge port. Hold the compressor port fitting with a backup wrench to prevent component damage. Unthread completely and separate the hose. Cap or plug the compressor port immediately. Remove and discard old O-rings from both the hose and compressor port.
6. 6

   Remove mounting brackets and extract hose
   The high-side hose is secured to the chassis or body with one or more mounting brackets or clips. Remove any 10mm bolts securing brackets. Note the exact position of any insulation or protective sleeves on the hose. Carefully extract the hose from the engine bay, noting its routing path for installation of the new hose.
7. 7

   Prepare new high-side hose
   Unpack the new high-side hose and verify it matches the old hose in length and fitting configuration. Install new O-rings at all connection points (typically 2 per fitting, 4 total). Lightly coat each O-ring with fresh PAG 46 oil using your finger or applicator. Do not over-oil as this can cause contamination. Add approximately 20ml (0.7 oz) of PAG oil into the new hose through one of the fittings to replace oil lost with the old hose.
8. 8

   Install new hose and route properly
   Route the new high-side hose along the same path as the original, ensuring it does not contact sharp edges, hot components, or moving parts. Install any protective sleeves or insulation in their original positions. Secure mounting brackets and clips, ensuring the hose is properly supported without excessive tension or sharp bends.
9. 9

   Connect hose at compressor
   Remove the cap from the compressor discharge port. Verify the new O-rings are properly seated in the hose fitting. Thread the fitting onto the compressor port by hand until finger-tight. Using a torque wrench and the appropriate socket or crow's foot adapter, tighten to specification. Use a backup wrench on the compressor port to prevent component rotation.
   Torque spec

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

    Connect hose at condenser
    Remove the cap from the condenser port. Verify new O-rings are properly seated. Thread the fitting onto the condenser by hand until finger-tight. Torque to specification using a torque wrench, with a backup wrench on the condenser fitting to prevent damage.
    Torque spec

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

    Evacuate AC system
    Connect the AC service machine to both service ports. Run a vacuum on the system for a minimum of 30 minutes, preferably 45 minutes. The system should achieve and hold a vacuum of at least 29 inches Hg (mercury). After evacuation, close the valves and observe the vacuum gauge for 10 minutes. The vacuum should hold steady, indicating no leaks. If vacuum drops, there is a leak that must be found and repaired.
    ⚠Proper evacuation is critical to remove moisture and air from the system. Insufficient evacuation will cause poor AC performance and compressor damage.
12. 12

    Recharge AC system
    Using the AC service machine, recharge the system with R134a refrigerant. The 2019-2024 RAV4 2.5L system capacity is approximately 580-620 grams (1.28-1.37 lbs). Charge to the exact specification on the underhood label. Follow the service machine's procedure for charging, monitoring both high and low side pressures. Do not overcharge the system.
13. 13

    Test for leaks and verify operation
    With the system charged, start the engine and turn on the AC to maximum cold, maximum fan speed. Allow to run for 5 minutes. Use a refrigerant leak detector to carefully check all connections, especially the newly installed fittings at the compressor and condenser. Check for proper AC operation: cold air from vents, appropriate cycling of compressor clutch, and normal pressure readings on gauges.

Reassembly

1. Reinstall engine cover if equipped by aligning grommets and pressing firmly until seated
2. Verify all tools and equipment are removed from engine bay
3. Double-check that all mounting brackets are secure and hose routing is correct

Verification

• Start engine and run AC system for 10 minutes at various settings
• Verify cold air output from all vents with temperature below 50°F at maximum cold setting
• Check that compressor clutch engages and disengages normally
• Verify no unusual noises from compressor or AC system
• Perform final leak check at all fittings with refrigerant detector
• Confirm high-side pressure reaches approximately 200-250 psi at idle with ambient temperature of 80°F
• Confirm low-side pressure maintains approximately 25-35 psi under same conditions
• Verify no refrigerant odor in cabin or engine bay

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