A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL; 2024 MY RAV4 HV [10/2023

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM100000002FQXX
Model Year Start: 2024	Model: RAV4 HV	Prod Date Range: [10/2023 - ]
Title: A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL; 2024 MY RAV4 HV [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 engine unit 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
*: When performing learning using the Techstream. Click here
Auxiliary battery terminal is disconnected/reconnected	Perform steering sensor zero point calibration	Lane control system
		Parking support brake system (for HV model)*
		Pre-collision system
	Reset back door close position	Power back door system
	Back door lock initialization	Power door lock control system
Replacement of ECM	Perform Vehicle Identification Number (VIN) registration	DTC P063051 is output
Replacement of ECM	Grille shutter switch specification infomation	Vehicle control history (RoB) [X260E] is stored
Replacement of engine assembly 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 engine coolant temperature sensor 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.
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
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
	Parking assist ECU initialization	Panoramic view monitor system (for HV model)
Front wheel alignment adjustment	Perform "Reset Memory" 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.)
Front bumper assembly (Including removal and installation)	Front television camera view adjustment	Panoramic view monitor system (for HV model)

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

PROCEDURE

1. REMOVE DRIVE SHAFT BEARING BRACKET

(a) Remove the 3 bolts and drive shaft bearing bracket.

2. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY

(a) Remove the bolt and 2 nuts.

	Bolt
	Nut

(b) Using an E8 "TORX" socket wrench, remove the 2 stud bolts and compressor assembly with pulley.

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

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

(b) Remove the bolt and the No. 2 water by-pass pipe sub-assembly.

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

(a) Remove the bolt.

(b) Slide the clip and disconnect the flow shutting valve (water by-pass hose assembly) from the water by-pass outlet sub-assembly.

5. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

(a) for Type A:

(1) Remove the 3 bolts and the No. 1 exhaust manifold heat insulator from the exhaust manifold.

(b) for Type B:

(1) Remove the 5 bolts and the No. 1 exhaust manifold heat insulator from the exhaust manifold.

6. REMOVE MANIFOLD STAY

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7. REMOVE EXHAUST MANIFOLD

(a) Using a 12 mm deep socket wrench, remove the 7 nuts and separate the exhaust manifold from the cylinder head sub-assembly.

(b) Remove the exhaust manifold to head gasket from the cylinder head sub-assembly.

8. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

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9. REMOVE EGR COOLER ASSEMBLY

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

(1) Remove the 2 bolts, 3 nuts, EGR cooler assembly, EGR cooler gasket and EGR valve gasket.

	Bolt
	Nut

(d) Type B:

(1) Remove the 3 bolts, 2 nuts, EGR cooler assembly, EGR cooler gasket and EGR valve gasket.

	Bolt
	Nut

10. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

Click here

11. REMOVE NO. 4 WATER BY-PASS HOSE

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

12. REMOVE EGR VALVE ASSEMBLY

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

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

*a	Pin
*b	Hole

13. REMOVE NO. 3 WATER BY-PASS PIPE

(a) Using an 8 mm socket wrench, remove the bolt and No. 3 water by-pass pipe from the intake manifold.

(b) Slide the clip and disconnect the No. 3 water by-pass pipe from the water outlet.

14. REMOVE NO. 2 WATER BY-PASS PIPE

(a) Remove the bolt (A).

(b) Using an 8 mm socket wrench, remove the 2 bolts (B) and No. 2 water by-pass pipe.

15. REMOVE INTAKE MANIFOLD

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16. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

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17. DISCONNECT FUEL TUBE SUB-ASSEMBLY

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18. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 1 fuel pipe sub-assembly.

	Union Nut
	Bolt

(b) Remove the bolt and No. 1 fuel pipe sub-assembly.

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

Click here

20. REMOVE NO. 7 WATER BY-PASS HOSE

(a) Slide the 2 clips and remove the No. 7 water by-pass hose.

21. REMOVE SENSOR WIRE

(a) Disconnect the 4 connectors.

(b) Detach the 3 clamps.

22. REMOVE NO. 6 ENGINE WIRE

(a) Disconnect the 4 connectors.

(b) Detach the 2 clamps.

23. REMOVE WIRE HARNESS CLAMP BRACKET

(a) Using an 8 mm socket wrench, remove the 2 bolts and wire harness clamp bracket from the No. 1 ventilation case.

24. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

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25. REMOVE NO. 1 DELIVERY PIPE SPACER

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26. REMOVE INJECTOR VIBRATION INSULATOR

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27. REMOVE NO. 5 ENGINE WIRE

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28. REMOVE PORT FUEL INJECTOR ASSEMBLY

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29. REMOVE FUEL DELIVERY PIPE

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30. REMOVE DIRECT FUEL INJECTOR ASSEMBLY

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31. REMOVE FUEL INJECTOR SEAL

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32. REMOVE IGNITION COIL ASSEMBLY

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33. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

(a) Remove the engine oil level dipstick.

(b) Using an 8 mm socket wrench, remove the bolt and engine oil level dipstick guide from the cylinder head sub-assembly.

34. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

(a) Remove the bolt and No. 3 exhaust manifold heat insulator from the cylinder block sub-assembly.