Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM1000000026TKU
Model Year Start: 2023 Model: RAV4 HV Prod Date Range: [10/2022 - 10/2023]
Title: A25A-FXS (ENGINE MECHANICAL): CYLINDER HEAD GASKET: REMOVAL; 2023 MY RAV4 HV [10/2022 - 10/2023]

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 cylinder head gasket removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedure

Effect/Inoperative Function when Necessary Procedure not Performed

Link

*: When performing learning using the Techstream.

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; PARK ASSIST / MONITORING: PARKING SUPPORT BRAKE SYSTEM (for HV Model): CALIBRATION

Auxiliary battery terminal is disconnected/reconnected

Perform steering sensor zero point calibration

Lane control system

2022 - 2024 MY RAV4 RAV4 HV [12/2021 -        ]; PRE-COLLISION: PRE-COLLISION SYSTEM: INITIALIZATION

Parking support brake system (for HV model)*

Pre-collision system

Reset back door close position

Power back door system (for HV model)

2019 - 2023 MY RAV4 HV [11/2018 - 10/2023]; DOOR / HATCH: POWER BACK DOOR SYSTEM (for HV Model): INITIALIZATION

Back door lock initialization

Power door lock control system

2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; DOOR LOCK: POWER DOOR LOCK CONTROL SYSTEM: INITIALIZATION

Replacement of ECM

Perform Vehicle Identification Number (VIN) registration

DTC P063051 is output

2021 - 2024 MY RAV4 RAV4 HV [08/2020 -        ]; A25A-FXS (ENGINE CONTROL): SFI SYSTEM: REGISTRATION

Grille shutter switch specification infomation

Vehicle control history (RoB) [X260E] is stored

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

  • Gas leak from exhaust system is repaired
  • Replacement of throttle body with motor assembly
  • Replacement of cam timing control motor with EDU assembly
  • Removal and installation of a cam timing control motor with EDU assembly
  • Replacement of camshaft timing gear assembly
  • Removal and installation of a camshaft timing gear assembly
  • Replacement of cylinder head sub-assembly
  • Replacement of camshaft (for intake or exhaust camshaft)
  • Replacement of camshaft timing exhaust gear assembly
  • Replacement of port fuel injector assembly
  • Replacement of direct fuel injector assembly
  • Replacement of fuel pump assembly (for high pressure side)
  • Replacement of spark plug
  • Replacement of ignition coil assembly
  • Replacement of EGR valve assembly
  • Replacement of knock control sensor
  • Replacement of air fuel ratio sensor (sensor 2)

Inspection after repair

  • Poor idle, etc.
  • Engine start function, etc.

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

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

2019 - 2024 MY RAV4 HV [02/2019 -        ]; HYBRID / BATTERY CONTROL: MOTOR GENERATOR CONTROL SYSTEM (for AWD with NICKEL METAL HYDRIDE BATTERY): UTILITY

Replacement of hybrid vehicle transaxle assembly

  • Resolver learning
  • Initialize resolver

Suspension, tires, etc.

(The vehicle height changes because of suspension or tire replacement)

Television camera assembly optical axis (Back camera position setting)

Parking assist monitor system

2023 - 2024 MY RAV4 RAV4 HV [10/2022 -        ]; PARK ASSIST / MONITORING: PARKING ASSIST MONITOR SYSTEM: CALIBRATION

Parking assist ECU initialization

Panoramic view monitor system (for HV model)

2023 - 2024 MY RAV4 HV [10/2022 -        ]; PARK ASSIST / MONITORING: PANORAMIC VIEW MONITOR SYSTEM (for HV Model): CALIBRATION

Front wheel alignment adjustment

  1. Perform "Reset Memory"
  2. Perform "Calibration"
  • DTCs are stored
  • ABS warning light illuminates
  • Brake system warning light (yellow indicator) illuminates
  • Slip indicator light illuminates
  • Brake control disabled or malfunctions (brake drag, etc.)

2022 - 2024 MY RAV4 RAV4 HV [12/2021 -        ]; BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: ELECTRONICALLY CONTROLLED BRAKE SYSTEM (w/o Vacuum Brake Booster): UTILITY

Front bumper assembly (Including removal and installation)

Front television camera view adjustment

Panoramic view monitor system (for HV model)

2023 - 2024 MY RAV4 HV [10/2022 -        ]; PARK ASSIST / MONITORING: PANORAMIC VIEW MONITOR SYSTEM (for HV Model): CALIBRATION

NOTICE:

  • After the ignition switch is turned off, the audio and visual system records various types of memory and settings. As a result, after turning the ignition switch off, make sure to wait at least 2 minutes before disconnecting the cable from the negative (-) auxiliary battery terminal.
  • When the cable is disconnected from the negative (-) auxiliary battery terminal and the security lock setting has been enabled, multi-display operations will be disabled upon next startup unless the password is entered. Be sure to check the security lock setting before disconnecting the cable from the negative (-) auxiliary battery terminal.
  • 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. INSTALL ENGINE ASSEMBLY TO ENGINE STAND

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL

2. REMOVE ENGINE HANGERS

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

3. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL+

4. REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL+

5. REMOVE FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY)

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL+

6. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL+

7. REMOVE MANIFOLD STAY

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

8. REMOVE EXHAUST MANIFOLD

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL+

9. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

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

10. REMOVE EGR COOLER ASSEMBLY

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL+

11. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

Click here 2022 - 2024 MY RAV4 HV [12/2021 -        ]; A25A-FXS (EMISSION CONTROL): EGR VALVE: REMOVAL+

12. REMOVE NO. 4 WATER BY-PASS HOSE

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL+

13. REMOVE EGR VALVE ASSEMBLY

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL+

14. REMOVE NO. 3 WATER BY-PASS PIPE

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL+

15. REMOVE NO. 2 WATER BY-PASS PIPE

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL+

16. REMOVE INTAKE MANIFOLD

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

17. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

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

18. DISCONNECT FUEL TUBE SUB-ASSEMBLY

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (FUEL): FUEL PUMP (for High Pressure): REMOVAL+

19. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL+

20. REMOVE FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (FUEL): FUEL PUMP (for High Pressure): REMOVAL+

21. REMOVE NO. 7 WATER BY-PASS HOSE

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL+

22. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): REMOVAL+

23. REMOVE NO. 1 DELIVERY PIPE SPACER

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): REMOVAL+

24. REMOVE INJECTOR VIBRATION INSULATOR

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): REMOVAL+

25. REMOVE NO. 5 ENGINE WIRE

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): REMOVAL+

26. REMOVE PORT FUEL INJECTOR ASSEMBLY

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): REMOVAL+

27. REMOVE FUEL DELIVERY PIPE

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (FUEL): FUEL INJECTOR (for Direct Injection): REMOVAL+

28. REMOVE DIRECT FUEL INJECTOR ASSEMBLY

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (FUEL): FUEL INJECTOR (for Direct Injection): REMOVAL+

29. REMOVE FUEL INJECTOR SEAL

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (FUEL): FUEL INJECTOR (for Direct Injection): REMOVAL+

30. REMOVE IGNITION COIL ASSEMBLY

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

31. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL+

32. REMOVE OIL PRESSURE CONTROL VALVE ASSEMBLY

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

33. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side)

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

34. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side)

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

35. REMOVE CAM TIMING OIL CONTROL SOLENOID ASSEMBLY

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

36. REMOVE CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (ENGINE CONTROL): CAMSHAFT TIMING CONTROL MOTOR: REMOVAL+

37. DISCONNECT NO. 1 WATER BY-PASS HOSE

(a) Slide the clip and disconnect the No. 1 water by-pass hose from the cylinder block sub-assembly.

38. DISCONNECT NO. 2 WATER BY-PASS HOSE

(a) Slide the clip and disconnect the No. 2 water by-pass hose from the No. 1 water by-pass pipe sub-assembly.

39. REMOVE CRANKSHAFT PULLEY ASSEMBLY

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

40. REMOVE WATER OUTLET

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

41. REMOVE OUTLET WATER BY-PASS SUB-ASSEMBLY

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

42. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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

43. REMOVE SPARK PLUG TUBE GASKET

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

44. REMOVE ENGINE MOUNTING BRACKET RH

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

45. REMOVE NO. 2 TIMING CHAIN COVER ASSEMBLY

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

46. REMOVE TIMING CHAIN COVER OIL SEAL

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

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

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

48. REMOVE OIL PUMP DRIVE CHAIN SUB-ASSEMBLY

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

49. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

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

50. REMOVE CHAIN SUB-ASSEMBLY

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

51. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

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

52. REMOVE CHAIN TENSIONER SLIPPER

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

53. REMOVE NO. 1 CHAIN VIBRATION DAMPER

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

54. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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

55. REMOVE TIMING CHAIN COVER ASSEMBLY

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

56. REMOVE FUEL PUMP LIFTER GUIDE

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

57. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

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

58. REMOVE CAMSHAFT BEARING CAP

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

59. REMOVE CAMSHAFT

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

60. REMOVE NO. 2 CAMSHAFT

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

61. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

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

62. REMOVE VALVE LASH ADJUSTER ASSEMBLY

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

63. REMOVE VALVE STEM CAP

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

64. REMOVE CYLINDER HEAD SUB-ASSEMBLY

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

65. REMOVE CYLINDER HEAD GASKET

(a) Remove the cylinder head gasket from the cylinder block sub-assembly.

66. INSPECT CYLINDER HEAD SET BOLT

Click here 2019 - 2024 MY RAV4 HV [11/2018 -        ]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: INSPECTION+

67. INSPECT CYLINDER HEAD SUB-ASSEMBLY

Click here 2019 - 2024 MY RAV4 HV [11/2018 -        ]; A25A-FXS (ENGINE MECHANICAL): CYLINDER HEAD: INSPECTION+