Last Modified: 05-08-2025 6.11:8.1.0 Doc ID: RM1000000021JTP
Model Year Start: 2022 Model: RAV4 HV Prod Date Range: [12/2021 -           ]
Title: A25A-FXS (EMISSION CONTROL): EGR COOLER: REMOVAL; 2022 - 2025 MY RAV4 HV [12/2021 -        ]

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 cooler 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 inverter with converter assembly

Resolver learning
  • DTCs are stored
  • Slight vibration at a vehicle speed of 5 km/h (3 mph) or less
  • Shock or vibration during acceleration

for AWD with NICKEL METAL HYDRIDE BATTERY:

2019 - 2025 MY RAV4 HV [02/2019 -        ]; HYBRID / BATTERY CONTROL: MOTOR GENERATOR CONTROL SYSTEM (for AWD with NICKEL METAL HYDRIDE BATTERY): UTILITY

for LITHIUM-ION BATTERY:

2020 - 2025 MY RAV4 HV [06/2020 -        ]; HYBRID / BATTERY CONTROL: MOTOR GENERATOR CONTROL SYSTEM (for LITHIUM-ION BATTERY): UTILITY

Gas leak from exhaust system is repaired

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

2022 - 2024 MY RAV4 HV [12/2021 - 11/2024]; A25A-FXS (ENGINE CONTROL): SFI SYSTEM: INITIALIZATION 2025 MY RAV4 HV [11/2024 -        ]; A25A-FXS (ENGINE CONTROL): SFI SYSTEM: INITIALIZATION

PROCEDURE

1. DRAIN ENGINE COOLANT (for Engine)

Click here 2022 - 2025 MY RAV4 HV [12/2021 -        ]; MAINTENANCE: A25A-FXS COOLANT (for Engine): REPLACEMENT+

2. REMOVE HYBRID MOTOR CONTROL INVERTER ASSEMBLY

Click here 2022 MY RAV4 HV [12/2021 - 10/2022]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER (for AWD): REMOVAL 2023 MY RAV4 HV [10/2022 - 10/2023]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER (for AWD): REMOVAL 2024 - 2025 MY RAV4 HV [10/2023 -        ]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER (for AWD): REMOVAL

3. REMOVE EGR COOLER ASSEMBLY

(a) Slide the 2 clips and disconnect the No. 3 water by-pass hose and No. 4 water by-pass hose from the EGR cooler assembly.

*1

No. 3 Water By-pass Hose

*2

No. 4 Water By-pass Hose

(b) Type A:

(1) Remove the 3 bolts, 2 nuts and EGR cooler assembly from the cylinder head sub-assembly and EGR valve assembly.

*a

Bolt or Nut

(c) Type B:

(1) Remove the 2 bolts, 3 nuts and EGR cooler assembly from the cylinder head sub-assembly and EGR valve assembly.

(d) Remove the EGR valve gasket from the EGR cooler assembly.

*1

EGR Valve Gasket

*2

EGR Cooler Gasket

(e) Remove the EGR cooler gasket from the EGR cooler assembly.