Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000001FENX
Model Year Start: 2019 Model: RAV4 HV Prod Date Range: [11/2018 - 08/2020]
Title: A25A-FXS (EMISSION CONTROL): EGR VALVE: INSTALLATION; 2019 - 2020 MY RAV4 HV [11/2018 - 08/2020]

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 EGR VALVE ASSEMBLY

(a) Using an 8 mm socket wrench, install the EGR valve assembly to the EGR valve bracket with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) Align and fit the hole of the EGR valve bracket to the pin of the camshaft housing.

*a

Pin

*b

Hole

(c) Using the 8 mm socket wrench, install the EGR valve assembly with the EGR valve bracket to the camshaft housing with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(d) Using an 8 mm socket wrench, connect the fuel pipe sub-assembly to the EGR valve bracket with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(e) Connect the No. 4 water by-pass hose to the EGR valve assembly, and slide the clip to secure the hose.

(f) Connect the No. 8 water by-pass hose to the EGR valve assembly, and slide the clip to secure the hose.

2. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

(a) Install a new EGR inlet gasket to the intake manifold.

(b) Install a new EGR valve adapter gasket to the No. 1 EGR pipe sub-assembly.

(c) Using an 8 mm socket wrench, install the No. 1 EGR pipe sub-assembly to the intake manifold and EGR valve assembly with the 4 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

3. CONNECT EGR COOLER ASSEMBLY

(a) Install a new EGR valve gasket to the EGR valve assembly.

NOTICE:

Make sure that the claws of the EGR valve gasket are toward the EGR valve assembly side.

*a

Claw

(b) Connect the EGR cooler assembly to the EGR valve assembly with the 2 bolts.

Torque:

24 N·m {245 kgf·cm, 18 ft·lbf}

4. CONNECT ENGINE WIRE

(a) Attach the 2 wire harness clamps to connect the engine wire.

(b) Install the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(c) Connect the EGR valve assembly connector.

(d) Attach the 3 hose clamps to connect the No. 1 fuel vapor feed hose and No. 2 fuel vapor feed hose.

*1

No. 1 Fuel Vapor Feed Hose

*2

No. 2 Fuel Vapor Feed Hose

5. ADD ENGINE COOLANT (for Engine)

Click here 2019 MY RAV4 HV [11/2018 - 02/2019]; MAINTENANCE: A25A-FXS COOLANT (for Engine): REPLACEMENT+ 2019 - 2021 MY RAV4 HV [02/2019 - 12/2021]; MAINTENANCE: A25A-FXS COOLANT (for Engine): REPLACEMENT+

6. INSPECT FOR COOLANT LEAK (for Engine)

Click here 2019 MY RAV4 HV [11/2018 - 02/2019]; A25A-FXS (COOLING): COOLING SYSTEM: ON-VEHICLE INSPECTION+ 2019 - 2024 MY RAV4 HV [02/2019 -        ]; A25A-FXS (COOLING): COOLING SYSTEM: ON-VEHICLE INSPECTION+

7. INSPECT FOR EXHAUST GAS LEAK

Click here 2019 MY RAV4 HV [11/2018 - 02/2019]; A25A-FXS (INTAKE / EXHAUST): EXHAUST PIPE: INSTALLATION+ 2019 - 2020 MY RAV4 HV [02/2019 - 08/2020]; A25A-FXS (INTAKE / EXHAUST): EXHAUST PIPE: INSTALLATION+