A25A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION; 2021 MY RAV4 [08/2020

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM100000001RCDC
Model Year Start: 2021	Model: RAV4	Prod Date Range: [08/2020 - 12/2021]
Title: A25A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION; 2021 MY RAV4 [08/2020 - 12/2021]

INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:

The engine assembly with transaxle is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop or the engine assembly with transaxle may fall off the engine lifter.
To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

PROCEDURE

1. INSTALL ENGINE MOUNTING BRACKET SUB-ASSEMBLY LH

(a) Install the engine mounting bracket sub-assembly LH to the vehicle body with the 4 bolts.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

NOTICE:

Temporarily install the bolt (A), and then tighten the 4 bolts in the order of (B), (C), (D) and (A).

2. INSTALL ENGINE MOUNTING INSULATOR LH

HINT:

Perform this procedure only when replacement of the engine mounting insulator LH is necessary.

for 2WD:
Click here
for AWD:
Click here

3. INSTALL ENGINE MOUNTING SPACER

HINT:

Perform this procedure only when replacement of the engine mounting spacer is necessary.

(a) Install the engine mounting spacer to the vehicle body with the 2 bolts.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

NOTICE:

Temporarily install the bolt (A), and then tighten the 2 bolts in the order of (B) and (A).

4. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

HINT:

Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.

(a) Install the engine mounting insulator sub-assembly RH with the 2 bolts and nut.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

NOTICE:

Temporarily install the bolt (A), and then tighten the 2 bolts and nut in the order of (B), (A) and (C).

(b) Connect the No. 2 ground wire to the engine mounting insulator sub-assembly RH with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

(d) Attach the 2 clamps and connect the wire harness to the radiator reserve tank assembly.

(e) Attach the clamp.

(f) Connect the No. 6 water by-pass hose.

(g) Attach the 2 clamps to connect the suction pipe sub-assembly and air conditioning tube and accessory assembly.

*1	Suction Pipe Sub-assembly
*2	Air Conditioning Tube And Accessory Assembly

(h) Connect the connector.

5. INSTALL ENGINE HANGERS

Click here

6. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND

(a) Remove the engine assembly from the engine stand.

7. INSTALL ENGINE WIRE

(a) Install the engine wire to the engine assembly.

8. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

Click here

9. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

Click here

10. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

for 2WD:
Click here
for AWD:
Click here

11. INSTALL STARTER ASSEMBLY

w/ Stop And Start System:
Click here
w/o Stop And Start System:
Click here

12. INSTALL FLYWHEEL HOUSING SIDE COVER

w/ Stop And Start System:
Click here
w/o Stop And Start System:
Click here

13. INSTALL REAR ENGINE MOUNTING BRACKET SUB-ASSEMBLY

for 2WD:
Click here
for AWD:
Click here

14. INSTALL REAR ENGINE MOUNTING INSULATOR (for AWD)

HINT:

Perform this procedure only when replacement of the rear engine mounting insulator is necessary.

Click here

15. INSTALL PROPELLER SHAFT HEAT INSULATOR (for AWD)

Click here

16. INSTALL REAR ENGINE MOUNTING INSULATOR (for 2WD)

HINT:

Perform this procedure only when replacement of the rear engine mounting insulator is necessary.

Click here

17. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET

for 2WD:
Click here
for AWD:
Click here

18. INSTALL FRONT ENGINE MOUNTING INSULATOR

HINT:

Perform this procedure only when replacement of the front engine mounting insulator is necessary.

for 2WD:
Click here
for AWD:
Click here

19. INSTALL VACUUM SWITCHING VALVE (for Active Control Engine Mount System)

Click here

20. INSTALL FRONT FRAME ASSEMBLY

for 2WD:
Click here
for AWD:
Click here

21. CONNECT WIRE HARNESS

for 2WD:
Click here
for AWD:
Click here

22. INSTALL STEERING GEAR HEAT INSULATOR

Click here

23. INSTALL BREATHER PLUG HOSE

for 2WD:
Click here
for AWD:
Click here

24. CONNECT WATER BY-PASS HOSE ASSEMBLY

for 2WD:
Click here
for AWD:
Click here

25. INSTALL FLOW SHUTTING VALVE (NO. 1 WATER BY-PASS HOSE)

Click here

26. CONNECT VACUUM HOSE

for 2WD:
Click here
for AWD:
Click here

27. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

for 2WD:
Click here
for AWD:
Click here

28. INSTALL FLYWHEEL HOUSING UNDER COVER

(a) Install the flywheel housing under cover to the cylinder block sub-assembly.

29. REMOVE ENGINE HANGERS

(a) Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger from the cylinder head sub-assembly and engine mounting bracket RH.

30. INSTALL FUEL DELIVERY GUARD

(a) Install the fuel delivery guard to the engine mounting bracket RH with the bolt.

Torque:

40 N·m {408 kgf·cm, 30 ft·lbf}

31. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

HINT:

Perform inspection after repair after replacing the engine assembly.

Click here

(a) Set the engine assembly with transaxle on an engine lifter.

Attachments

NOTICE:

Using height adjustment attachments and plate lift attachments, keep the engine assembly with transaxle level.
Do not perform any procedures while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.

(b) Operate the engine lifter and install the engine assembly with transaxle to the vehicle.

CAUTION:

Do not raise the engine assembly with transaxle more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

NOTICE:

Make sure that the engine assembly with transaxle is clear of all wiring and hoses.
While raising the engine assembly with transaxle into the vehicle, do not allow it to contact the vehicle.

(c) Install the front bumper extension sub-assembly LH and front bumper extension sub-assembly RH to the front frame assembly and vehicle body with the 2 bolts (A), 2 bolts (B) and 4 nuts.

*1	Front Bumper Extension Sub-assembly LH
*2	Front Bumper Extension Sub-assembly RH
*3	Rear Front Suspension Member Brace LH
*4	Rear Front Suspension Member Brace RH
	Bolt
	Nut

Torque:

Bolt (A) :

135 N·m {1377 kgf·cm, 100 ft·lbf}

Bolt (B) :

9.5 N·m {97 kgf·cm, 84 in·lbf}

Nut :

12.5 N·m {127 kgf·cm, 9 ft·lbf}

(d) Install the rear front suspension member brace LH and rear front suspension member brace RH to the front frame assembly and vehicle body with the 2 bolts (C) and 4 bolts (D).

Torque:

Bolt (C) :

135 N·m {1377 kgf·cm, 100 ft·lbf}

Bolt (D) :

60 N·m {612 kgf·cm, 44 ft·lbf}

(e) Install the engine mounting insulator LH to the engine mounting bracket sub-assembly LH with the bolt and nut.

Torque:

42 N·m {428 kgf·cm, 31 ft·lbf}

NOTICE:

While holding the bolt in place, tighten the nut.

(f) Install the engine mounting insulator sub-assembly RH to the engine mounting bracket RH with the 3 bolts and nut.

Torque:

Bolt :

72 N·m {734 kgf·cm, 53 ft·lbf}

Nut :

42 N·m {428 kgf·cm, 31 ft·lbf}

32. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY

Click here

33. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH

for 2WD:
Click here
for AWD:
Click here

34. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

for 2WD:
Click here
for AWD:
Click here

35. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

for 2WD:
Click here
for AWD:
Click here

36. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

Click here

37. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

HINT:

Use the same procedure described for the LH side.

38. CONNECT TIE ROD ASSEMBLY LH

Click here

39. CONNECT TIE ROD ASSEMBLY RH

HINT:

Use the same procedure described for the LH side.

40. CONNECT FRONT STABILIZER LINK ASSEMBLY LH

Click here

41. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

HINT:

Use the same procedure described for the LH side.

42. CONNECT FRONT SPEED SENSOR LH

Click here

43. CONNECT FRONT SPEED SENSOR RH

HINT:

Use the same procedure described for the LH side.

44. INSTALL FRONT AXLE SHAFT NUT LH

Click here

45. INSTALL FRONT AXLE SHAFT NUT RH

HINT:

Use the same procedure described for the LH side.

46. STAKE FRONT AXLE SHAFT NUT LH

Click here

47. STAKE FRONT AXLE SHAFT NUT RH

HINT:

Use the same procedure described for the LH side.

48. TEMPORARILY INSTALL PROPELLER SHAFT ASSEMBLY (for AWD)

Click here

49. TIGHTEN PROPELLER SHAFT ASSEMBLY (for AWD)

Click here

50. INSPECT AND ADJUST JOINT ANGLE (for AWD)

Click here

51. INSTALL LOWER NO. 1 FRONT FLOOR HEAT INSULATOR (for AWD)

Click here

52. INSTALL FRONT EXHAUST PIPE ASSEMBLY

Click here

53. INSTALL NO. 1 FLOOR UNDER COVER (w/ Cover)

Click here

54. INSTALL FRONT FLOOR COVER RH (w/ Cover)

Click here

55. INSTALL NO. 2 FLOOR UNDER COVER (w/ Cover)

Click here

56. INSTALL FRONT FLOOR COVER LH (w/ Cover)

Click here

57. INSTALL NO. 5 WATER BY-PASS HOSE

(a) Install the No. 5 water by-pass hose to the radiator assembly and No. 3 water by-pass pipe, and slide the 2 clips to secure it.

NOTICE:

Align the direction of the claw on the clip with the paint mark on the hose.
Make sure the No. 5 water by-pass hose is securely inserted to the stopper.

*a	View A	*b	View B
*c	360°	*d	120°
*e	Paint Mark	*f	Upper Side
*g	Front Side	*h	Rear Side
*i	2 to 7 mm (0.0787 to 0.276 in.)	*j	2 to 5 mm (0.0787 to 0.197 in.)

58. CONNECT WIRE HARNESS

(a) Connect the wire harness to the vehicle body with the bolt.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(b) Attach the clamp.

(d) Connect the 5 connectors to the engine room relay block and junction block assembly.

(e) Install the nut to the engine room relay block and junction block assembly.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(f) Attach the 3 claws and install the No. 2 relay block cover.

59. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE SUB-ASSEMBLY

Click here

60. CONNECT SUCTION HOSE SUB-ASSEMBLY

Click here

61. CONNECT NO. 2 RADIATOR HOSE

(a) Connect the No. 2 radiator hose to the radiator assembly and slide the clip to secure it.

NOTICE:

Align the direction of the claw on the clip with the paint mark on the hose.
Make sure the No. 2 radiator hose is securely inserted to the stopper.

*a	View A	*b	120°
*c	Paint Mark	*d	Upper Side
*e	RH Side	*f	2 to 5 mm (0.0787 to 0.197 in.)

62. CONNECT NO. 1 RADIATOR HOSE

(a) Connect the No. 1 radiator hose to the water outlet and slide the clip to secure it.

NOTICE:

Align the direction of the claw on the clip with the paint mark on the hose.
Make sure the No. 1 radiator hose is securely inserted to the stopper.

*a	View A	*b	90°
*c	Paint Mark	*d	Upper Side
*e	Front Side	*f	2 to 7 mm (0.0787 to 0.276 in.)

63. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Connect the fuel tube sub-assembly.

(1) Connect the fuel tube sub-assembly to the fuel pipe.

Click here

(b) Install the No. 1 fuel pipe clamp to the fuel tube connector.

Click here

64. CONNECT OUTLET HEATER WATER HOSE

(a) Align the protrusion of the No. 2 water by-pass pipe sub-assembly with the cutout in the outlet heater hose connector and securely insert the outlet heater water hose connector to the stopper of the pipe.

*a	Protrusion
*b	Cutout

(b) Push in the retainer.

*a	Retainer
	Push
	Push in

(c) Check that the No. 2 water by-pass pipe sub-assembly and outlet heater water hose connector are securely connected by pulling on them.

65. CONNECT INLET HEATER WATER HOSE

(a) Align the protrusions of the inlet heater water hose connector with the cutouts in the flow shutting valve (water by-pass hose assembly) and securely insert the inlet heater water hose connector to the stopper of the pipe.

*a	Protrusion
*b	Cutout

(b) Push in the retainer.

*a	Retainer
	Push
	Push in

(c) Check that the flow shutting valve (water by-pass hose assembly) and inlet heater water hose connector are securely connected by pulling on them.

66. CONNECT NO. 1 VACUUM HOSE CONNECTOR

Click here

67. CONNECT UNION TO CHECK VALVE HOSE

(a) Connect the union to check valve hose to the vacuum pump assembly and slide the clip to secure it.

68. CONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Connect the No. 1 fuel vapor feed hose to the purge VSV and slide the clip to secure it.

69. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Connect the transmission control cable assembly to the No. 1 transmission control cable bracket with a new clip.

(b) Connect the transmission control cable assembly to the transmission control shaft lever as shown in the illustration.

NOTICE:

Before installing the transmission control cable assembly, check that the park/neutral position switch assembly and shift lever are in N.

*a	Correct
*b	Incorrect

70. CONNECT NO. 3 ENGINE WIRE

(a) Connect the No. 3 engine wire to the automatic transaxle assembly with the bolt.

Torque:

20 N·m {204 kgf·cm, 15 ft·lbf}

(b) Attach the clamp to the bracket.

71. INSTALL BATTERY CLAMP SUB-ASSEMBLY

(a) Install the battery clamp sub-assembly with the 3 bolts.

Torque:

18.5 N·m {189 kgf·cm, 14 ft·lbf}

(b) Attach the 2 claws and connect the engine room main wire to the No. 2 engine wire.

*1	Engine Room Main Wire
*2	No. 2 Engine Wire
*3	Positive (+) Battery Terminal

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

(d) Attach the 2 clamps and connect the engine room main wire and No. 2 engine wire to the battery clamp sub-assembly.

(e) Attach the 2 clamps to the battery clamp sub-assembly.

72. INSTALL BATTERY

Click here

73. INSTALL ECM

Click here

74. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE

Click here

75. INSTALL INLET AIR CLEANER ASSEMBLY

Click here

76. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

(a) Attach the 3 clips to install the No. 1 engine cover sub-assembly.

NOTICE:

Securely attach the clips.
If the clips are forcibly attached or struck with an object, they may be damaged.

77. INSPECT VACUUM HOSES

(a) Inspect the vacuum hoses.

for 2WD

for AWD

78. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

Click here

79. INSPECT SHIFT LEVER POSITION

for 2WD:
Click here
for AWD:
Click here

80. ADJUST SHIFT LEVER POSITION

for 2WD:
Click here
for AWD:
Click here

81. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

Click here

82. ADD ENGINE OIL

Click here

83. ADD SPECIFIED AMOUNT OF AUTOMATIC TRANSAXLE FLUID

for 2WD:
Click here
for AWD:
Click here

84. ADD TRANSFER OIL (for AWD)

GF1A:
Click here
GF2A:
Click here

85. ADD ENGINE COOLANT

Click here

86. ADJUST AUTOMATIC TRANSAXLE FLUID

for 2WD:
Click here
for AWD:
Click here

87. WARM UP ENGINE

Click here

88. INSPECT FOR ENGINE OIL LEAK

Click here

89. INSPECT FOR COOLANT LEAK

Click here

90. INSPECT FOR REFRIGERANT LEAK

Click here

91. INSPECT FOR FUEL LEAK

Click here

92. INSPECT FOR EXHAUST GAS LEAK

Click here

93. CHECK ENGINE OIL LEVEL

Click here

94. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR

Click here

95. INSTALL FRONT LOWER BUMPER ABSORBER

(a) Attach the 2 claws to install the front lower bumper absorber.

(b) Install the 5 bolts.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

96. INSTALL FRONT BUMPER ASSEMBLY

for Off Road Package:
Click here
except Off Road Package:
Click here

97. INSTALL FRONT FENDER APRON SEAL LH

(a) Install the front fender apron seal LH with the 2 bolts and clip.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

	Bolt
	Clip

98. INSTALL FRONT FENDER APRON SEAL RH

(a) Install the front fender apron seal RH with the 2 bolts and clip.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

	Bolt
	Clip

99. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY

(a) Install the No. 2 engine under cover assembly with the 2 bolts, 2 screws and 6 clips.

Torque:

Bolt :

7.5 N·m {76 kgf·cm, 66 in·lbf}

	Bolt
	Screw

100. INSTALL NO. 1 ENGINE UNDER COVER

(a) Attach the guide and install the No. 1 engine under cover.

(b) Install the 2 bolts and 10 screws. (Short Type Front Fender Front Splash Shield)

Torque:

Bolt :

7.5 N·m {76 kgf·cm, 66 in·lbf}

Torque:

Bolt :

7.5 N·m {76 kgf·cm, 66 in·lbf}

*a	Short Type Front Fender Front Splash Shield	-	-
	Bolt		Screw

101. INSTALL FRONT FENDER FRONT SPLASH SHIELD LH

(a) for Short Type:

(1) Attach the clip to install the front fender front splash shield LH.

(2) Install the 3 screws.

(b) for Long Type:

(1) Attach the clip to install the front fender front splash shield LH.

(2) Install the 4 screws.

102. INSTALL FRONT FENDER FRONT SPLASH SHIELD RH

(a) for Short Type:

(1) Attach the clip to install the front fender front splash shield RH.

(2) Install the 3 screws.

(b) for Long Type:

(1) Attach the clip to install the front fender front splash shield RH.

(2) Install the 4 screws.

103. INSTALL FRONT WHEELS

Click here

104. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

105. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

Click here

106. INSPECT THROTTLE BODY WITH MOTOR ASSEMBLY

Click here

107. INSPECT IGNITION TIMING

Click here

108. INSPECT ENGINE IDLE SPEED

Click here

109. INSPECT CO/HC

Click here

110. CHECK SPEED SENSOR SIGNAL

Click here