Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000001HGV0
Model Year Start: 2019 Model: RAV4 HV Prod Date Range: [02/2019 - 10/2019]
Title: A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL; 2019 MY RAV4 HV [02/2019 - 10/2019]

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

Link

*: When performing learning using the Techstream.

Click here 2019 - 2022 MY RAV4 HV [02/2019 - 10/2022]; 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

2019 - 2021 MY RAV4 RAV4 HV [11/2018 - 12/2021]; PRE-COLLISION: PRE-COLLISION SYSTEM: INITIALIZATION

Parking support brake system (for HV model)*

Pre-collision system

Lighting system (EXT)(w/ AFS)

Memorize steering angle neutral point

Parking assist monitor system

2019 - 2022 MY RAV4 RAV4 HV [11/2018 - 10/2022]; PARK ASSIST / MONITORING: PARKING ASSIST MONITOR SYSTEM: INITIALIZATION

Panoramic view monitor system (for HV model)

2019 - 2022 MY RAV4 HV [11/2018 - 10/2022]; PARK ASSIST / MONITORING: PANORAMIC VIEW MONITOR SYSTEM (for HV Model): INITIALIZATION

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 (w/ Canister Pump Module)

Perform Vehicle Identification Number (VIN) registration

DTC P063051 is output

2019 - 2020 MY RAV4 RAV4 HV [02/2019 - 08/2020]; A25A-FXS (ENGINE CONTROL): SFI SYSTEM (w/ Canister Pump Module): REGISTRATION

Grille shutter switch specification infomation

Vehicle control history (RoB) [X260E] is stored

2019 MY RAV4 RAV4 HV [02/2019 - 10/2019]; A25A-FXS (ENGINE CONTROL): SFI SYSTEM (w/ Canister Pump Module): INITIALIZATION

Replacement of ECM (w/o Canister Pump Module)

Perform Vehicle Identification Number (VIN) registration

DTC P063051 is output

2019 - 2020 MY RAV4 HV [11/2018 - 08/2020]; A25A-FXS (ENGINE CONTROL): SFI SYSTEM (w/o Canister Pump Module): REGISTRATION

  • 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.

2019 MY RAV4 RAV4 HV [02/2019 - 10/2019]; A25A-FXS (ENGINE CONTROL): SFI SYSTEM (w/ Canister Pump Module): INITIALIZATION (w/ Canister Pump Module)

2019 - 2020 MY RAV4 HV [11/2018 - 08/2020]; A25A-FXS (ENGINE CONTROL): SFI SYSTEM (w/o Canister Pump Module): INITIALIZATION (w/o Canister Pump Module)

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 - 2020 MY RAV4 HV [11/2018 - 08/2020]; HYBRID / BATTERY CONTROL: MOTOR GENERATOR CONTROL SYSTEM (for 2WD with NICKEL METAL HYDRIDE BATTERY): UTILITY (for 2WD)

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

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

2019 - 2022 MY RAV4 RAV4 HV [11/2018 - 10/2022]; PARK ASSIST / MONITORING: PARKING ASSIST MONITOR SYSTEM: CALIBRATION

  • Parking assist ECU initialization
  • Adjust steering angle

Panoramic view monitor system (for HV model)

2019 - 2022 MY RAV4 HV [11/2018 - 10/2022]; PARK ASSIST / MONITORING: PANORAMIC VIEW MONITOR SYSTEM (for HV Model): CALIBRATION

Replacement of headlight ECU sub-assembly LH

  • Synchronize the vehicle information
  • Perform headlight ECU sub-assembly LH initialization

Lighting system (EXT)(w/ Headlight ECU)

2019 - 2021 MY RAV4 RAV4 HV [11/2018 - 12/2021]; LIGHTING (EXT): LIGHTING SYSTEM (w/ Headlight ECU without AFS): INITIALIZATION

Suspension, tires, etc.

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

Perform headlight ECU sub-assembly LH initialization

Front wheel alignment adjustment

  1. Clear the zero point calibration data and stored linear solenoid valve calibration data.
  2. Perform initialization and calibration of the linear solenoid valve.
  3. Perform yaw rate and acceleration sensor zero point calibration.
  • DTCs are stored
  • ABS warning light illuminates
  • Brake warning light / yellow (minor malfunction) illuminates
  • Slip indicator light illuminates
  • VSC disabled or malfunctions

2019 - 2021 MY RAV4 RAV4 HV [02/2019 - 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)

2019 - 2022 MY RAV4 HV [11/2018 - 10/2022]; PARK ASSIST / MONITORING: PANORAMIC VIEW MONITOR SYSTEM (for HV Model): CALIBRATION

NOTICE:

  • After the power switch is turned off, the radio and display receiver assembly records various types of memory and settings. As a result, after turning the power switch off, be sure to wait for the time specified in the following table before disconnecting the cable from the negative (-) auxiliary battery terminal.

    Waiting Time before Disconnecting Cable from Negative (-) Auxiliary Battery Terminal

    System Name

    See Procedure

    Vehicle enrolled in Toyota Entune system or safety connect system

    6 minutes

    Vehicle not enrolled in Toyota Entune system and safety connect system

    1 minute

  • 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. 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.

(c) Remove the 2 bolts and water hose clamp bracket.

5. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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

6. REMOVE MANIFOLD STAY

Click here 2019 - 2020 MY RAV4 HV [02/2019 - 08/2020]; A25A-FXS (INTAKE / EXHAUST): EXHAUST MANIFOLD: REMOVAL+

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

Click here 2019 - 2020 MY RAV4 HV [02/2019 - 08/2020]; A25A-FXS (ENGINE CONTROL): THROTTLE BODY: REMOVAL+

9. REMOVE EGR COOLER ASSEMBLY

(a) Slide the clip and disconnect the water hose from the EGR cooler assembly.

*1

No. 3 Water By-pass Hose

*2

Water Hose

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

(c) Remove the 5 bolts, EGR cooler assembly, EGR cooler gasket and EGR valve gasket.

10. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

Click here 2019 - 2020 MY RAV4 HV [02/2019 - 08/2020]; A25A-FXS (EMISSION CONTROL): EGR VALVE: REMOVAL+

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 and disconnect the fuel pipe sub-assembly from the EGR valve bracket.

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

(d) Remove the EGR valve assembly vertically.

*a

Pin

*b

Hole

(e) Using an 8 mm socket wrench, remove the bolt and EGR valve bracket.

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

Click here 2019 - 2020 MY RAV4 HV [02/2019 - 08/2020]; A25A-FXS (INTAKE / EXHAUST): INTAKE MANIFOLD: REMOVAL+

16. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

Click here 2019 - 2020 MY RAV4 HV [02/2019 - 08/2020]; A25A-FXS (INTAKE / EXHAUST): INTAKE MANIFOLD: REMOVAL+

17. DISCONNECT FUEL TUBE SUB-ASSEMBLY

Click here 2019 - 2020 MY RAV4 HV [02/2019 - 08/2020]; A25A-FXS (FUEL): FUEL PUMP (for High Pressure): REMOVAL+

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.

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

Click here 2019 - 2020 MY RAV4 HV [02/2019 - 08/2020]; A25A-FXS (FUEL): FUEL PUMP (for High Pressure): REMOVAL+

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.

(c) Using an 8 mm socket wrench, remove the bolt and sensor wire from the water inlet with thermostat sub-assembly.

22. REMOVE NO. 6 ENGINE WIRE

(a) Disconnect the 4 connectors.

(b) Detach the 2 clamps.

(c) Remove the 2 nuts and No. 6 engine wire from the wire harness clamp bracket.

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

Click here 2019 - 2020 MY RAV4 HV [02/2019 - 06/2020]; A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): REMOVAL+

25. REMOVE NO. 1 DELIVERY PIPE SPACER

Click here 2019 - 2020 MY RAV4 HV [02/2019 - 06/2020]; A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): REMOVAL+

26. REMOVE INJECTOR VIBRATION INSULATOR

Click here 2019 - 2020 MY RAV4 HV [02/2019 - 06/2020]; A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): REMOVAL+

27. REMOVE NO. 5 ENGINE WIRE

Click here 2019 - 2020 MY RAV4 HV [02/2019 - 06/2020]; A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): REMOVAL+

28. REMOVE PORT FUEL INJECTOR ASSEMBLY

Click here 2019 - 2020 MY RAV4 HV [02/2019 - 06/2020]; A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): REMOVAL+

29. REMOVE FUEL DELIVERY PIPE

Click here 2019 - 2020 MY RAV4 HV [02/2019 - 08/2020]; A25A-FXS (FUEL): FUEL INJECTOR (for Direct Injection): REMOVAL+

30. REMOVE DIRECT FUEL INJECTOR ASSEMBLY

Click here 2019 - 2020 MY RAV4 HV [02/2019 - 08/2020]; A25A-FXS (FUEL): FUEL INJECTOR (for Direct Injection): REMOVAL+

31. REMOVE FUEL INJECTOR SEAL

Click here 2019 - 2020 MY RAV4 HV [02/2019 - 08/2020]; A25A-FXS (FUEL): FUEL INJECTOR (for Direct Injection): REMOVAL+

32. REMOVE IGNITION COIL ASSEMBLY

Click here 2019 - 2020 MY RAV4 HV [02/2019 - 08/2020]; A25A-FXS (ENGINE CONTROL): IGNITION COIL AND SPARK PLUG: REMOVAL+

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.

(c) Remove the O-ring from the engine oil level dipstick guide.

34. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

(a) Remove the 2 bolts and No. 3 exhaust manifold heat insulator from the cylinder block sub-assembly.