Last Modified: 05-08-2025 6.11:8.1.0 Doc ID: RM100000001FEMW
Model Year Start: 2019 Model: RAV4 Prod Date Range: [11/2018 - 08/2020]
Title: A25A-FKS (EMISSION CONTROL): EGR VALVE: REMOVAL; 2019 - 2020 MY RAV4 [11/2018 - 08/2020]

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 EGR valve assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedures

Effect/Inoperative Function when Necessary Procedure not Performed

Link
  • Replacement of EGR valve assembly
  • Gas leak from exhaust system is repaired

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

2019 MY RAV4 [11/2018 - 10/2019]; A25A-FKS (ENGINE CONTROL): SFI SYSTEM (w/ Canister Pump Module): INITIALIZATION 2020 MY RAV4 [10/2019 - 08/2020]; A25A-FKS (ENGINE CONTROL): SFI SYSTEM (w/ Canister Pump Module): INITIALIZATION (w/ Canister Pump Module)

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

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 - 2025 MY RAV4 RAV4 HV [11/2018 -        ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

PROCEDURE

1. DRAIN ENGINE COOLANT

Click here 2019 - 2025 MY RAV4 [11/2018 -        ]; A25A-FKS (COOLING): COOLANT: REPLACEMENT+

2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

Click here 2019 MY RAV4 [11/2018 - 10/2019]; A25A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+ 2020 MY RAV4 [10/2019 - 08/2020]; A25A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

3. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

Click here 2019 - 2020 MY RAV4 [11/2018 - 08/2020]; A25A-FKS (ENGINE CONTROL): THROTTLE BODY: REMOVAL+

4. REMOVE EGR COOLER ASSEMBLY

Click here 2019 - 2020 MY RAV4 [11/2018 - 08/2020]; A25A-FKS (EMISSION CONTROL): EGR COOLER: REMOVAL+

5. DISCONNECT ENGINE WIRE

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

*a

No. 5 Engine Wire Connector

*b

EGR Valve Assembly Connector

(b) Disconnect the EGR valve assembly connector.

(c) Remove the bolt.

(d) Disengage the 2 wire harness clamps and disconnect the engine wire.

6. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

(a) Using an 8 mm socket wrench, remove the 4 bolts and No. 1 EGR pipe sub-assembly from the intake manifold and EGR valve assembly.

(b) Remove the EGR valve adapter gasket from the No. 1 EGR pipe sub-assembly.

(c) Remove the EGR inlet gasket from the intake manifold.

7. REMOVE EGR VALVE ASSEMBLY

(a) Slide the clip and disconnect the No. 8 water by-pass hose from the EGR valve assembly.

(b) Slide the clip and remove the No. 4 water by-pass hose from the EGR valve assembly.

(c) Remove the 2 bolts and EGR cooler bracket from the EGR valve bracket and water outlet.

(d) Using an 8 mm socket wrench, remove the bolt and disconnect the fuel pipe sub-assembly from the EGR valve bracket.

(e) Using an 8 mm socket wrench, remove the bolt.

(f) Remove the EGR valve assembly with the EGR valve bracket from the camshaft housing vertically.

*a

Pin

*b

Hole

(g) Using the 8 mm socket wrench, remove the bolt and EGR valve assembly from the EGR valve bracket.