This procedure replaces the blower motor resistor, which controls the HVAC blower motor speed on 2019-2024 Toyota RAV4 vehicles with the 2.5L I4 engine.

Warnings

Tools required

Parts

• Blower motor resistor assembly × 1 — 87138-42080 or equivalent OEM part

Preparation

1. Park vehicle on level surface and turn off ignition
2. Allow HVAC system to cool for at least 15 minutes if recently operated
3. Gather all tools and replacement parts before beginning
4. Test current blower motor operation to confirm resistor failure (typically only high speed works when resistor fails)

Procedure

1. 1

   Remove lower glove box panel
   Open the glove box and remove all contents. Locate the lower trim panel beneath the glove box in the passenger footwell. Use the trim tool to carefully pry out the panel retaining clips starting from the sides, then pull the panel away from the dashboard to access the area behind it.
2. 2

   Locate blower motor resistor
   With the lower panel removed, look up toward the HVAC housing on the passenger side. The blower motor resistor is mounted to the HVAC case with two screws and has a wire harness connector attached. It is typically located just forward of the blower motor itself.
3. 3

   Disconnect electrical connector
   Press the locking tab on the resistor wire harness connector and pull straight out to disconnect. Note the connector orientation for reassembly. Inspect the connector terminals for signs of heat damage or corrosion.
   ⚠If connector terminals show melting or severe corrosion, the connector pigtail may also need replacement to prevent repeat failure
4. 4

   Remove resistor mounting screws
   Using the Phillips screwdriver, remove the two screws securing the blower motor resistor to the HVAC housing. Support the resistor with your hand to prevent it from falling once the screws are removed.
5. 5

   Extract blower motor resistor
   Carefully pull the resistor assembly straight out from the HVAC housing. There may be a rubber seal or gasket around the resistor body. Inspect the mounting area in the HVAC housing for debris or leaves that may have contributed to overheating.
6. 6

   Clean mounting area
   Use the shop vacuum or compressed air to remove any debris, leaves, or dust from the resistor mounting location on the HVAC housing. Check that the air passages are clear. This prevents premature failure of the new resistor.
7. 7

   Prepare new resistor
   Remove the new blower motor resistor from packaging. Verify it matches the old unit in connector type and mounting pattern. If the new resistor includes a seal or gasket, ensure it is properly positioned on the resistor body.
8. 8

   Install new resistor
   Insert the new blower motor resistor into the HVAC housing, ensuring it is fully seated and properly oriented. The seal should compress evenly against the housing. Install the two mounting screws and tighten to specification using the torque wrench.
   Torque spec

   Resistor Screws2 Nm (1.5 lb-ft)
9. 9

   Reconnect electrical connector
   Plug the wire harness connector onto the new resistor until you hear or feel the locking tab click into place. Gently tug on the connector to verify it is securely locked.
10. 10

    Test blower motor operation
    Before reinstalling the trim panel, turn the ignition to ON (or start the engine). Test the blower motor at all speed settings (low, medium-low, medium-high, and high). Verify smooth operation at each speed with no unusual noises or hesitation.
    ℹ️All blower speeds should now function properly if the resistor was the only failed component
11. 11

    Reinstall lower panel
    Once blower operation is verified, align the lower trim panel with the mounting clips and press firmly until all clips are fully seated. Ensure the panel is flush with surrounding trim.

Reassembly

1. Reinstall any items removed from the glove box
2. Verify all trim panels are securely fastened with no gaps or loose clips
3. No calibration or system reset is required after this repair

Verification

• Turn ignition to ON and test blower motor at all four speed settings
• Verify smooth operation with consistent airflow at each speed level
• Listen for any unusual noises such as clicking or buzzing from the blower area
• Confirm proper air temperature control remains functional
• Check that lower trim panel is secure and properly aligned

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