This procedure covers the removal and replacement of the AC pressure sensor on a 2019-2024 Toyota RAV4 2.5L I4 FWD engine, including proper system evacuation and recharge procedures.

Warnings

Tools required

Parts

• AC pressure sensor × 1 — 88719-42020 or equivalent
• AC system O-rings × 2 — Use OEM specification
• PAG oil (ND-11) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely if recently operated
3. Ensure AC recovery/evacuation/recharge machine is ready and functional
4. Locate AC pressure sensor on the high-pressure AC line near the condenser on driver side of engine bay
5. Disconnect negative battery terminal and wait 90 seconds

Procedure

1. 1

   Recover AC refrigerant
   Connect AC recovery machine to the vehicle's service ports (low and high side). Follow machine manufacturer instructions to fully recover all refrigerant from the system. Record the amount recovered for proper recharge quantity.
2. 2

   Access AC pressure sensor
   The AC pressure sensor is located on the high-pressure line near the condenser, driver side of engine bay. It has a 2-pin electrical connector and is threaded into the aluminum AC line. May need to remove plastic engine cover by pulling upward on clips if present for better access.
3. 3

   Disconnect electrical connector
   Press the locking tab on the AC pressure sensor electrical connector and carefully pull straight away from the sensor. Inspect connector for corrosion or damage.
4. 4

   Remove AC pressure sensor
   Using a 19mm wrench or socket, carefully unthread the AC pressure sensor from the high-pressure line in a counterclockwise direction. Remove sensor completely and inspect the O-ring sealing surface on the AC line for damage or debris.
   ⚠If any refrigerant releases during removal, STOP immediately. System was not fully evacuated and must be properly recovered before proceeding.
5. 5

   Prepare new sensor
   Remove new AC pressure sensor from packaging. Remove protective caps from sensor threads. Install new O-rings onto the sensor body, ensuring they are properly seated in the groove. Apply a small amount of fresh PAG ND-11 oil to the O-rings using a clean finger or applicator.
6. 6

   Install new AC pressure sensor
   Thread the new AC pressure sensor into the high-pressure line by hand, ensuring it threads smoothly without cross-threading. Once hand-tight, use a 19mm wrench or torque wrench to tighten to 20 Nm (15 lb-ft) per AC line fitting specification. Do not overtighten as this can damage the O-ring seal or aluminum threads.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
7. 7

   Reconnect electrical connector
   Push the electrical connector firmly onto the AC pressure sensor until the locking tab clicks into place. Gently tug on the connector to verify it is fully seated and locked.
8. 8

   Evacuate AC system
   Connect AC evacuation machine to service ports. Evacuate the AC system for a minimum of 30 minutes to remove all air and moisture. Perform a vacuum hold test for at least 15 minutes to verify system integrity and proper sensor seal.
9. 9

   Recharge AC system
   Using the AC recharge machine, add the correct amount of R-1234yf refrigerant as recorded during recovery (typically 490-510 grams for this vehicle). Add appropriate amount of PAG ND-11 oil if system was significantly depleted. Follow machine instructions for proper charging procedure.
10. 10

    Reconnect battery and finalize
    Reconnect the negative battery terminal. Reinstall engine cover if removed. Start vehicle and verify no warning lights are present on instrument cluster.

Reassembly

1. Ensure electrical connector is fully locked onto sensor
2. Verify all tools and equipment are removed from engine bay
3. Reinstall any engine covers or components removed for access

Verification

• Start engine and turn AC system to maximum cold setting
• Allow system to run for 5-10 minutes and verify cold air output from vents
• Check for refrigerant leaks around sensor using electronic leak detector or soap solution
• Use scan tool to verify AC pressure sensor is providing valid readings (typically 120-200 PSI at idle when ambient temp is 70-80°F)
• Verify no AC-related warning lights or fault codes are present
• Confirm compressor engages and disengages normally during operation

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