A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: INSTALLATION; 2020 MY RAV4 HV [06/2020

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM100000001P8A2
Model Year Start: 2020	Model: RAV4 HV	Prod Date Range: [06/2020 - 08/2020]
Title: A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: INSTALLATION; 2020 MY RAV4 HV [06/2020 - 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.

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PROCEDURE

1. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

(a) Install the No. 3 exhaust manifold heat insulator to the cylinder block sub-assembly with the bolt.

Torque:

16 N·m {163 kgf·cm, 12 ft·lbf}

2. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

(a) Apply a light coat of engine oil to a new O-ring.

(b) Install the O-ring to the engine oil level dipstick guide.

(c) Using an 8 mm socket wrench, install the engine oil level dipstick guide to the cylinder head sub-assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(d) Install the engine oil level dipstick.

3. INSTALL IGNITION COIL ASSEMBLY

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4. INSTALL FUEL INJECTOR SEAL

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5. INSTALL DIRECT FUEL INJECTOR ASSEMBLY

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6. INSTALL FUEL DELIVERY PIPE

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7. INSTALL PORT FUEL INJECTOR ASSEMBLY

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8. INSTALL NO. 5 ENGINE WIRE

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9. INSTALL INJECTOR VIBRATION INSULATOR

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10. INSTALL NO. 1 DELIVERY PIPE SPACER

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11. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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12. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Using an 8 mm socket wrench, install the wire harness clamp bracket to the No. 1 ventilation case with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

13. INSTALL NO. 6 ENGINE WIRE

(a) Install the No. 6 engine wire to the wire harness clamp bracket with the 2 nuts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) Attach the 2 clamps.

14. INSTALL SENSOR WIRE

(a) Using an 8 mm socket wrench, install the sensor wire to the water inlet with thermostat sub-assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) Attach the 3 clamps.

15. INSTALL NO. 7 WATER BY-PASS HOSE

(a) Install the No. 7 water by-pass hose and slide the 2 clips to secure them.

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

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

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

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19. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe side of the No. 1 fuel pipe sub-assembly.

Torque:

Specified tightening torque :

35 N·m {357 kgf·cm, 26 ft·lbf}

NOTICE:

Do not adjust the torque in the loosening direction.

HINT:

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
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When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)

*a	17 mm Union Nut Wrench
*b	Torque Wrench Fulcrum Length

(b) Using a 17 mm union nut wrench, tighten the union nut on the fuel pump assembly side of the No. 1 fuel pipe sub-assembly.

Torque:

Specified tightening torque :

35 N·m {357 kgf·cm, 26 ft·lbf}

NOTICE:

Do not adjust the torque in the loosening direction.

HINT:

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
Click here
When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)

20. CONNECT FUEL TUBE SUB-ASSEMBLY

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21. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET

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22. INSTALL INTAKE MANIFOLD

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23. INSTALL NO. 2 WATER BY-PASS PIPE

(a) Install the bolt (A).

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(b) Using an 8 mm socket wrench, install the No. 2 water by-pass pipe with the 2 bolts (B) in the order shown in the illustration.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

24. INSTALL NO. 3 WATER BY-PASS PIPE

(a) Connect the No. 3 water by-pass pipe to the water outlet and slide the clip to secure it.

(b) Using an 8 mm socket wrench, install the No. 3 water by-pass pipe to the intake manifold with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

25. INSTALL EGR VALVE ASSEMBLY

(a) Using an 8 mm socket wrench, install 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 sub-assembly.

*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 sub-assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(d) Using the 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. 8 water by-pass hose to the EGR valve assembly and slide the clip to secure it.

26. INSTALL NO. 4 WATER BY-PASS HOSE

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

27. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

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28. INSTALL EGR COOLER ASSEMBLY

(a) Install the EGR cooler assembly, a new EGR cooler gasket and a new EGR valve gasket with the 5 bolts.

Torque:

24 N·m {245 kgf·cm, 18 ft·lbf}

(b) Connect the No. 3 water by-pass hose to the EGR cooler assembly and slide the clip to secure it.

29. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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30. INSTALL EXHAUST MANIFOLD

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31. INSTALL MANIFOLD STAY

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32. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

(a) Install the No. 1 exhaust manifold heat insulator to the exhaust manifold with the 5 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

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

(a) Install the water hose clamp bracket with the 2 bolts as shown in the illustration.

Torque:

13 N·m {133 kgf·cm, 10 ft·lbf}

NOTICE:

Temporarily install the bolt (A), and then tighten the 2 bolts in the order of (B) and (A).

(b) Connect the flow shutting valve (water by-pass hose assembly) to the water by-pass outlet sub-assembly and slide the clip to secure it.

NOTICE:

Make sure to slide the flow shutting valve (water by-pass hose assembly) until it contacts the hose stopper of the water by-pass outlet sub-assembly.
Make sure that the claws of the clip are within the location shown in the illustration.

*a	Paint Mark
*b	90° (Claw of Clip Location)

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

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

(a) Connect the No. 2 water by-pass pipe sub-assembly with the bolt.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

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

35. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

(a) Using an E8 "TORX" socket wrench, temporarily install the compressor assembly with pulley with the 2 stud bolts.

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

(b) Install the compressor assembly with pulley with the bolt and 2 nuts.

	Bolt
	Nut

Torque:

24.5 N·m {250 kgf·cm, 18 ft·lbf}

HINT:

Tighten the bolt and nuts in the order shown in the illustration.

36. INSTALL DRIVE SHAFT BEARING BRACKET

(a) Install the drive shaft bearing bracket with the 3 bolts.

Torque:

63.7 N·m {650 kgf·cm, 47 ft·lbf}