Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000001FC50
Model Year Start: 2019 Model: RAV4 HV Prod Date Range: [11/2018 - 02/2019]
Title: A25A-FXS (INTAKE / EXHAUST): INTAKE MANIFOLD: REMOVAL; 2019 MY RAV4 HV [11/2018 - 02/2019]

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during intake manifold removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedure

Effect/Inoperative Function when Necessary Procedure not Performed

Link
  • Replacement of throttle body assembly
  • Cleaning the deposits from the throttle body assembly
  • Replacement of EGR valve assembly
  • Gas leak from exhaust system is repaired

Inspection After Repair
  • Poor idle, etc.
  • Engine start function, etc.

2019 - 2020 MY RAV4 HV [11/2018 - 08/2020]; A25A-FXS (ENGINE CONTROL): SFI SYSTEM (w/o Canister Pump Module): INITIALIZATION

NOTICE:

This procedure includes the removal of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

PROCEDURE

1. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

Click here 2019 MY RAV4 HV [11/2018 - 02/2019]; A25A-FXS (ENGINE CONTROL): THROTTLE BODY: REMOVAL

2. REMOVE EGR VALVE ASSEMBLY

Click here 2019 MY RAV4 HV [11/2018 - 02/2019]; A25A-FXS (EMISSION CONTROL): EGR VALVE: REMOVAL

3. REMOVE E.F.I. VACUUM SENSOR ASSEMBLY (MANIFOLD ABSOLUTE PRESSURE SENSOR)

Click here 2019 - 2024 MY RAV4 HV [11/2018 -        ]; A25A-FXS (EMISSION CONTROL): VACUUM SENSOR: REMOVAL+

4. REMOVE PURGE VALVE (PURGE VSV)

Click here 2019 - 2024 MY RAV4 HV [11/2018 -        ]; A25A-FXS (EMISSION CONTROL): PURGE VALVE: REMOVAL+

5. DISCONNECT ENGINE WIRE

(a) Disconnect the No. 5 engine wire connector.

(b) Remove the bolt and disconnect the engine wire from the cylinder head sub-assembly.

(c) Remove the bolt.

(d) Detach the wire harness clamp and disconnect the engine wire from the intake manifold.

6. DISCONNECT NO. 3 WATER BY-PASS PIPE

(a) Slide the clip and disconnect the No. 5 water by-pass hose from the No. 3 water by-pass pipe.

(b) Using an 8 mm socket wrench, remove the bolt and disconnect the No. 3 water by-pass pipe from the intake manifold.

7. REMOVE NO. 2 WATER BY-PASS PIPE

(a) Detach the wire harness clamp and disconnect the HV air conditioning wire.

(b) Using an 8 mm socket wrench, remove the 2 bolts (A) and separate the No. 2 water by-pass pipe from the intake manifold.

(c) Remove the bolt (B) and No. 2 water by-pass pipe from the cylinder block sub-assembly.

8. REMOVE NO. 2 FUEL VAPOR FEED HOSE

(a) Remove the No. 2 fuel vapor feed hose from the intake manifold.

9. REMOVE INTAKE MANIFOLD

(a) w/o Stud Bolt:

(1) Remove the 5 bolts and intake manifold from the cylinder head sub-assembly.

(b) w/ Stud Bolt:

Bolt

Nut

(1) Remove the 3 bolts, 2 nuts and intake manifold from the cylinder head sub-assembly.

10. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

(a) Remove the No. 1 intake manifold to head gasket from the intake manifold.

11. REMOVE NO. 1 ENGINE COVER

(a) Remove the clip and No. 1 engine cover.

12. REMOVE VACUUM HOSE

(a) Remove the vacuum hose from the intake manifold.