Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM10000000224DK
Model Year Start: 2022 Model: RAV4 Prod Date Range: [12/2021 -           ]
Title: A25A-FKS (ENGINE MECHANICAL): CYLINDER HEAD GASKET: INSTALLATION; 2022 - 2024 MY RAV4 [12/2021 -        ]

INSTALLATION

CAUTION / NOTICE / HINT

NOTICE:

This procedure includes the installation 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. INSTALL CYLINDER HEAD GASKET

(a) Clean the cylinder block sub-assembly and cylinder head sub-assembly with solvent.

(b) Place a new cylinder head gasket on the cylinder block sub-assembly with the Lot No. stamp facing upward.

*a

Lot No.

Front of Engine

NOTICE:

Make sure that the cylinder head gasket is installed in the correct orientation.

2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

3. INSTALL NO. 2 CAMSHAFT

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

4. INSTALL CAMSHAFT

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

5. INSTALL CAMSHAFT BEARING CAP

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

6. INSTALL VALVE STEM CAP

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

7. INSTALL VALVE LASH ADJUSTER ASSEMBLY

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

8. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

9. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

10. INSTALL FUEL PUMP LIFTER GUIDE

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

11. INSTALL TIMING CHAIN COVER ASSEMBLY

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

12. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

13. SET NO. 1 CYLINDER TO TDC (COMPRESSION)

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

14. INSTALL NO. 1 CHAIN VIBRATION DAMPER

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

15. INSTALL CHAIN TENSIONER SLIPPER

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

16. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

17. INSTALL CHAIN SUB-ASSEMBLY

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

18. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

19. INSTALL OIL PUMP DRIVE CHAIN SUB-ASSEMBLY

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

20. SET NO. 1 CYLINDER TO TDC (COMPRESSION)

Click here 2020 - 2024 MY RAV4 [06/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: DISASSEMBLY+

21. INSTALL NO. 2 TIMING CHAIN COVER ASSEMBLY

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

22. INSTALL TIMING CHAIN COVER OIL SEAL

Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; A25A-FKS (ENGINE MECHANICAL): FRONT CRANKSHAFT OIL SEAL: INSTALLATION+

23. INSTALL SPARK PLUG TUBE GASKET

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

24. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

25. INSTALL OUTLET WATER BY-PASS SUB-ASSEMBLY

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

26. INSTALL WATER OUTLET

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

27. INSTALL CRANKSHAFT PULLEY ASSEMBLY

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

28. INSTALL VACUUM PUMP ASSEMBLY

Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; BRAKE SYSTEM (OTHER): VACUUM PUMP (for A25A-FKS): INSTALLATION+

29. CONNECT NO. 2 WATER BY-PASS HOSE (w/ Oil Cooler)

(a) Connect the No. 2 water by-pass hose to the water by-pass pipe sub-assembly and slide the clip to secure it.

30. CONNECT NO. 1 WATER BY-PASS HOSE (w/ Oil Cooler)

(a) Connect the No. 1 water by-pass hose to the cylinder block sub-assembly and slide the clip to secure it.

31. INSTALL CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE CONTROL): CAMSHAFT TIMING CONTROL MOTOR: INSTALLATION+

32. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY

Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; A25A-FKS (ENGINE CONTROL): CAMSHAFT OIL CONTROL SOLENOID: INSTALLATION+

33. INSTALL OIL PRESSURE CONTROL VALVE ASSEMBLY

Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; A25A-FKS (LUBRICATION): OIL PRESSURE SWITCHING VALVE: INSTALLATION+

34. INSTALL PURGE VALVE (PURGE VSV)

Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; A25A-FKS (EMISSION CONTROL): PURGE VALVE(w/ Canister Pump Module): INSTALLATION+

35. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

Click here 2022 - 2024 MY RAV4 [12/2021 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: INSTALLATION+

36. INSTALL IGNITION COIL ASSEMBLY

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE CONTROL): IGNITION COIL AND SPARK PLUG: INSTALLATION+

37. INSTALL FUEL INJECTOR SEAL

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (FUEL): FUEL INJECTOR (for Direct Injection): INSTALLATION+

38. INSTALL DIRECT FUEL INJECTOR ASSEMBLY

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (FUEL): FUEL INJECTOR (for Direct Injection): INSTALLATION+

39. INSTALL FUEL DELIVERY PIPE

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (FUEL): FUEL INJECTOR (for Direct Injection): INSTALLATION+

40. INSTALL PORT FUEL INJECTOR ASSEMBLY

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (FUEL): FUEL INJECTOR (for Port Injection): INSTALLATION+

41. INSTALL NO. 5 ENGINE WIRE

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (FUEL): FUEL INJECTOR (for Port Injection): INSTALLATION+

42. INSTALL INJECTOR VIBRATION INSULATOR

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (FUEL): FUEL INJECTOR (for Port Injection): INSTALLATION+

43. INSTALL NO. 1 DELIVERY PIPE SPACER

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (FUEL): FUEL INJECTOR (for Port Injection): INSTALLATION+

44. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (FUEL): FUEL INJECTOR (for Port Injection): INSTALLATION+

45. INSTALL NO. 7 WATER BY-PASS HOSE

Click here 2022 - 2024 MY RAV4 [12/2021 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: INSTALLATION+

46. TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (FUEL): FUEL PUMP (for High Pressure): INSTALLATION+

47. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (FUEL): FUEL PUMP (for High Pressure): INSTALLATION+

48. INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (FUEL): FUEL PUMP (for High Pressure): INSTALLATION+

49. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

Click here 2022 - 2024 MY RAV4 [12/2021 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: INSTALLATION+

50. CONNECT FUEL TUBE SUB-ASSEMBLY

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (FUEL): FUEL PUMP (for High Pressure): INSTALLATION+

51. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET

Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; A25A-FKS (INTAKE / EXHAUST): INTAKE MANIFOLD: INSTALLATION+

52. INSTALL INTAKE MANIFOLD

Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; A25A-FKS (INTAKE / EXHAUST): INTAKE MANIFOLD: INSTALLATION+

53. INSTALL NO. 2 WATER BY-PASS PIPE

Click here 2022 - 2024 MY RAV4 [12/2021 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: INSTALLATION+

54. INSTALL NO. 3 WATER BY-PASS PIPE

Click here 2022 - 2024 MY RAV4 [12/2021 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: INSTALLATION+

55. SET EGR VALVE ASSEMBLY

Click here 2022 - 2024 MY RAV4 [12/2021 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: INSTALLATION+

56. INSTALL NO. 4 WATER BY-PASS HOSE

Click here 2022 - 2024 MY RAV4 [12/2021 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: INSTALLATION+

57. INSTALL EGR COOLER ASSEMBLY

Click here 2022 - 2024 MY RAV4 [12/2021 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: INSTALLATION+

58. INSTALL EGR VALVE ASSEMBLY

Click here 2022 - 2024 MY RAV4 [12/2021 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: INSTALLATION+

59. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

Click here 2022 - 2024 MY RAV4 [12/2021 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: INSTALLATION+

60. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE CONTROL): THROTTLE BODY: INSTALLATION+

61. INSTALL EXHAUST MANIFOLD

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (INTAKE / EXHAUST): EXHAUST MANIFOLD: INSTALLATION+

62. INSTALL MANIFOLD STAY

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (INTAKE / EXHAUST): EXHAUST MANIFOLD: INSTALLATION+

63. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

Click here 2022 - 2024 MY RAV4 [12/2021 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: INSTALLATION+

64. INSTALL FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY)

Click here 2022 - 2024 MY RAV4 [12/2021 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: INSTALLATION+

65. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

Click here 2022 - 2024 MY RAV4 [12/2021 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: INSTALLATION+

66. INSTALL NO. 3 TIMING CHAIN COVER

Click here 2022 - 2024 MY RAV4 [12/2021 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: INSTALLATION+

67. INSTALL TIMING GEAR COVER INSULATOR

Click here 2022 - 2024 MY RAV4 [12/2021 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: INSTALLATION+

68. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

Click here 2022 - 2024 MY RAV4 [12/2021 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: INSTALLATION+

69. INSTALL NO. 2 ENGINE COVER

Click here 2022 - 2024 MY RAV4 [12/2021 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: INSTALLATION+

70. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

Click here 2022 - 2024 MY RAV4 [12/2021 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: INSTALLATION+

71. INSTALL GENERATOR ASSEMBLY

  • for 100 A, 130 A Type:

    Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; A25A-FKS (BATTERY / CHARGING): GENERATOR (for 100 A, 130 A Type): INSTALLATION+

  • for 150 A Type:

    Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; A25A-FKS (BATTERY / CHARGING): GENERATOR (for 150 A Type): INSTALLATION+

  • for VALEO Made:

    Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; A25A-FKS (BATTERY / CHARGING): GENERATOR (for VALEO Made): INSTALLATION+

72. INSTALL V-RIBBED BELT

Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; MAINTENANCE: A25A-FKS DRIVE BELT: INSTALLATION+

73. INSTALL ENGINE HANGERS

Click here 2022 MY RAV4 [12/2021 - 10/2022]; A25A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+ 2023 MY RAV4 [10/2022 - 10/2023]; A25A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+ 2024 MY RAV4 [10/2023 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

74. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND

Click here 2022 - 2024 MY RAV4 [12/2021 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION