Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000001RCDC
Model Year Start: 2021 Model: RAV4 Prod Date Range: [08/2020 - 12/2021]
Title: A25A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION; 2021 MY RAV4 [08/2020 - 12/2021]

INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:

  • The engine assembly with transaxle is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop or the engine assembly with transaxle may fall off the engine lifter.
  • To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

PROCEDURE

1. INSTALL ENGINE MOUNTING BRACKET SUB-ASSEMBLY LH

(a) Install the engine mounting bracket sub-assembly LH to the vehicle body with the 4 bolts.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

NOTICE:

Temporarily install the bolt (A), and then tighten the 4 bolts in the order of (B), (C), (D) and (A).

2. INSTALL ENGINE MOUNTING INSULATOR LH

HINT:

Perform this procedure only when replacement of the engine mounting insulator LH is necessary.

  • for 2WD:

    Click here 2020 - 2024 MY RAV4 [10/2019 -        ]; UB80E (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION+

  • for AWD:

    Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; UB80F (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION+

3. INSTALL ENGINE MOUNTING SPACER

HINT:

Perform this procedure only when replacement of the engine mounting spacer is necessary.

(a) Install the engine mounting spacer to the vehicle body with the 2 bolts.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

NOTICE:

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

4. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

HINT:

Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.

(a) Install the engine mounting insulator sub-assembly RH with the 2 bolts and nut.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

NOTICE:

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

(b) Connect the No. 2 ground wire to the engine mounting insulator sub-assembly RH with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(c) Install the radiator reserve tank assembly with the bolt and nut in the order shown in the illustration.

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

(d) Attach the 2 clamps and connect the wire harness to the radiator reserve tank assembly.

(e) Attach the clamp.

(f) Connect the No. 6 water by-pass hose.

(g) Attach the 2 clamps to connect the suction pipe sub-assembly and air conditioning tube and accessory assembly.

*1

Suction Pipe Sub-assembly

*2

Air Conditioning Tube And Accessory Assembly

(h) Connect the connector.

5. INSTALL ENGINE HANGERS

Click here 2021 MY RAV4 [08/2020 - 12/2021]; A25A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

6. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND

(a) Remove the engine assembly from the engine stand.

7. INSTALL ENGINE WIRE

(a) Install the engine wire to the engine assembly.

8. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; A25A-FKS (ENGINE MECHANICAL): REAR CRANKSHAFT OIL SEAL: INSTALLATION+

9. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; A25A-FKS (ENGINE MECHANICAL): REAR CRANKSHAFT OIL SEAL: INSTALLATION+

10. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

  • for 2WD:

    Click here 2020 - 2024 MY RAV4 [10/2019 -        ]; UB80E (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION+

  • for AWD:

    Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; UB80F (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION+

11. INSTALL STARTER ASSEMBLY

  • w/ Stop And Start System:

    Click here

  • w/o Stop And Start System:

    Click here 2020 - 2024 MY RAV4 [10/2019 -        ]; A25A-FKS (STARTING): STARTER (w/o Stop And Start System): INSTALLATION+

12. INSTALL FLYWHEEL HOUSING SIDE COVER

  • w/ Stop And Start System:

    Click here 2021 MY RAV4 [08/2020 - 12/2021]; A25A-FKS (STARTING): STARTER (w/ Stop And Start System): INSTALLATION+

  • w/o Stop And Start System:

    Click here 2020 - 2024 MY RAV4 [10/2019 -        ]; A25A-FKS (STARTING): STARTER (w/o Stop And Start System): INSTALLATION+

13. INSTALL REAR ENGINE MOUNTING BRACKET SUB-ASSEMBLY

  • for 2WD:

    Click here 2020 - 2024 MY RAV4 [10/2019 -        ]; UB80E (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION+

  • for AWD:

    Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; UB80F (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION+

14. INSTALL REAR ENGINE MOUNTING INSULATOR (for AWD)

HINT:

Perform this procedure only when replacement of the rear engine mounting insulator is necessary.

Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; UB80F (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION+

15. INSTALL PROPELLER SHAFT HEAT INSULATOR (for AWD)

Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; UB80F (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION+

16. INSTALL REAR ENGINE MOUNTING INSULATOR (for 2WD)

HINT:

Perform this procedure only when replacement of the rear engine mounting insulator is necessary.

Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; A25A-FKS (ENGINE CONTROL): ACTIVE CONTROL ENGINE MOUNT (for Rear Side): INSTALLATION+

17. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET

  • for 2WD:

    Click here 2020 - 2024 MY RAV4 [10/2019 -        ]; UB80E (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION+

  • for AWD:

    Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; UB80F (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION+

18. INSTALL FRONT ENGINE MOUNTING INSULATOR

HINT:

Perform this procedure only when replacement of the front engine mounting insulator is necessary.

  • for 2WD:

    Click here 2020 - 2024 MY RAV4 [10/2019 -        ]; UB80E (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION+

  • for AWD:

    Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; UB80F (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION+

19. INSTALL VACUUM SWITCHING VALVE (for Active Control Engine Mount System)

Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; A25A-FKS (ENGINE CONTROL): VACUUM SWITCHING VALVE (for Engine Mounting): INSTALLATION+

20. INSTALL FRONT FRAME ASSEMBLY

  • for 2WD:

    Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; FRONT SUSPENSION: FRONT SUSPENSION MEMBER (for Gasoline Model): INSTALLATION+

  • for AWD:

    Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; FRONT SUSPENSION: FRONT SUSPENSION MEMBER (for Gasoline Model): INSTALLATION+

21. CONNECT WIRE HARNESS

  • for 2WD:

    Click here 2020 - 2024 MY RAV4 [10/2019 -        ]; UB80E (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION+

  • for AWD:

    Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; UB80F (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION+

22. INSTALL STEERING GEAR HEAT INSULATOR

Click here 2019 - 2024 MY RAV4 RAV4 HV [02/2019 -        ]; STEERING GEAR / LINKAGE: STEERING GEAR: INSTALLATION+

23. INSTALL BREATHER PLUG HOSE

  • for 2WD:

    Click here 2020 - 2024 MY RAV4 [10/2019 -        ]; UB80E (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION+

  • for AWD:

    Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; UB80F (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION+

24. CONNECT WATER BY-PASS HOSE ASSEMBLY

  • for 2WD:

    Click here 2020 - 2024 MY RAV4 [10/2019 -        ]; UB80E (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION+

  • for AWD:

    Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; UB80F (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION+

25. INSTALL FLOW SHUTTING VALVE (NO. 1 WATER BY-PASS HOSE)

Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; A25A-FKS (COOLING): FLOW SHUTTING VALVE (for ATF): INSTALLATION+

26. CONNECT VACUUM HOSE

  • for 2WD:

    Click here 2020 - 2024 MY RAV4 [10/2019 -        ]; UB80E (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION+

  • for AWD:

    Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; UB80F (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION+

27. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

  • for 2WD:

    Click here 2020 - 2024 MY RAV4 [10/2019 -        ]; UB80E (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION+

  • for AWD:

    Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; UB80F (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION+

28. INSTALL FLYWHEEL HOUSING UNDER COVER

(a) Install the flywheel housing under cover to the cylinder block sub-assembly.

29. REMOVE ENGINE HANGERS

(a) Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger from the cylinder head sub-assembly and engine mounting bracket RH.

30. INSTALL FUEL DELIVERY GUARD

(a) Install the fuel delivery guard to the engine mounting bracket RH with the bolt.

Torque:

40 N·m {408 kgf·cm, 30 ft·lbf}

31. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

HINT:

Perform inspection after repair after replacing the engine assembly.

Click here 2021 MY RAV4 RAV4 HV [08/2020 - 12/2021]; A25A-FKS (ENGINE CONTROL): SFI SYSTEM: INITIALIZATION

(a) Set the engine assembly with transaxle on an engine lifter.

Attachments

-

-

NOTICE:

  • Using height adjustment attachments and plate lift attachments, keep the engine assembly with transaxle level.
  • Do not perform any procedures while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.

(b) Operate the engine lifter and install the engine assembly with transaxle to the vehicle.

CAUTION:

Do not raise the engine assembly with transaxle more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

NOTICE:

  • Make sure that the engine assembly with transaxle is clear of all wiring and hoses.
  • While raising the engine assembly with transaxle into the vehicle, do not allow it to contact the vehicle.

(c) Install the front bumper extension sub-assembly LH and front bumper extension sub-assembly RH to the front frame assembly and vehicle body with the 2 bolts (A), 2 bolts (B) and 4 nuts.

*1

Front Bumper Extension Sub-assembly LH

*2

Front Bumper Extension Sub-assembly RH

*3

Rear Front Suspension Member Brace LH

*4

Rear Front Suspension Member Brace RH

Bolt

Nut

Torque:

Bolt (A) :

135 N·m {1377 kgf·cm, 100 ft·lbf}

Bolt (B) :

9.5 N·m {97 kgf·cm, 84 in·lbf}

Nut :

12.5 N·m {127 kgf·cm, 9 ft·lbf}

(d) Install the rear front suspension member brace LH and rear front suspension member brace RH to the front frame assembly and vehicle body with the 2 bolts (C) and 4 bolts (D).

Torque:

Bolt (C) :

135 N·m {1377 kgf·cm, 100 ft·lbf}

Bolt (D) :

60 N·m {612 kgf·cm, 44 ft·lbf}

(e) Install the engine mounting insulator LH to the engine mounting bracket sub-assembly LH with the bolt and nut.

Torque:

42 N·m {428 kgf·cm, 31 ft·lbf}

NOTICE:

While holding the bolt in place, tighten the nut.

(f) Install the engine mounting insulator sub-assembly RH to the engine mounting bracket RH with the 3 bolts and nut.

Torque:

Bolt :

72 N·m {734 kgf·cm, 53 ft·lbf}

Nut :

42 N·m {428 kgf·cm, 31 ft·lbf}

32. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY

Click here 2019 - 2024 MY RAV4 RAV4 HV [02/2019 -        ]; STEERING GEAR / LINKAGE: STEERING GEAR: INSTALLATION+

33. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH

  • for 2WD:

    Click here 2021 - 2024 MY RAV4 RAV4 HV [08/2020 -        ]; DRIVE SHAFT / PROPELLER SHAFT: FRONT DRIVE SHAFT ASSEMBLY (for 2WD): INSTALLATION+

  • for AWD:

    Click here 2019 - 2024 MY RAV4 RAV4 HV [02/2019 -        ]; DRIVE SHAFT / PROPELLER SHAFT: FRONT DRIVE SHAFT ASSEMBLY (for AWD): INSTALLATION+

34. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

  • for 2WD:

    Click here 2021 - 2024 MY RAV4 RAV4 HV [08/2020 -        ]; DRIVE SHAFT / PROPELLER SHAFT: FRONT DRIVE SHAFT ASSEMBLY (for 2WD): INSTALLATION+

  • for AWD:

    Click here 2019 - 2024 MY RAV4 RAV4 HV [02/2019 -        ]; DRIVE SHAFT / PROPELLER SHAFT: FRONT DRIVE SHAFT ASSEMBLY (for AWD): INSTALLATION+

35. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

  • for 2WD:

    Click here 2021 - 2024 MY RAV4 RAV4 HV [08/2020 -        ]; DRIVE SHAFT / PROPELLER SHAFT: FRONT DRIVE SHAFT ASSEMBLY (for 2WD): INSTALLATION+

  • for AWD:

    Click here 2019 - 2024 MY RAV4 RAV4 HV [02/2019 -        ]; DRIVE SHAFT / PROPELLER SHAFT: FRONT DRIVE SHAFT ASSEMBLY (for AWD): INSTALLATION+

36. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

Click here 2019 - 2021 MY RAV4 RAV4 HV [02/2019 - 12/2021]; AXLE AND DIFFERENTIAL: FRONT AXLE HUB: INSTALLATION+

37. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

HINT:

Use the same procedure described for the LH side.

38. CONNECT TIE ROD ASSEMBLY LH

Click here 2019 - 2024 MY RAV4 RAV4 HV [02/2019 -        ]; STEERING GEAR / LINKAGE: STEERING GEAR: INSTALLATION+

39. CONNECT TIE ROD ASSEMBLY RH

HINT:

Use the same procedure described for the LH side.

40. CONNECT FRONT STABILIZER LINK ASSEMBLY LH

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; FRONT SUSPENSION: FRONT STABILIZER BAR: INSTALLATION+

41. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

HINT:

Use the same procedure described for the LH side.

42. CONNECT FRONT SPEED SENSOR LH

Click here 2019 - 2021 MY RAV4 RAV4 HV [02/2019 - 12/2021]; AXLE AND DIFFERENTIAL: FRONT AXLE HUB: INSTALLATION+

43. CONNECT FRONT SPEED SENSOR RH

HINT:

Use the same procedure described for the LH side.

44. INSTALL FRONT AXLE SHAFT NUT LH

Click here 2019 - 2021 MY RAV4 RAV4 HV [02/2019 - 12/2021]; AXLE AND DIFFERENTIAL: FRONT AXLE HUB: INSTALLATION+

45. INSTALL FRONT AXLE SHAFT NUT RH

HINT:

Use the same procedure described for the LH side.

46. STAKE FRONT AXLE SHAFT NUT LH

Click here 2019 - 2021 MY RAV4 RAV4 HV [02/2019 - 12/2021]; AXLE AND DIFFERENTIAL: FRONT AXLE HUB: INSTALLATION+

47. STAKE FRONT AXLE SHAFT NUT RH

HINT:

Use the same procedure described for the LH side.

48. TEMPORARILY INSTALL PROPELLER SHAFT ASSEMBLY (for AWD)

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; DRIVE SHAFT / PROPELLER SHAFT: PROPELLER SHAFT ASSEMBLY: INSTALLATION+

49. TIGHTEN PROPELLER SHAFT ASSEMBLY (for AWD)

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; DRIVE SHAFT / PROPELLER SHAFT: PROPELLER SHAFT ASSEMBLY: INSTALLATION+

50. INSPECT AND ADJUST JOINT ANGLE (for AWD)

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; DRIVE SHAFT / PROPELLER SHAFT: PROPELLER SHAFT ASSEMBLY: INSTALLATION+

51. INSTALL LOWER NO. 1 FRONT FLOOR HEAT INSULATOR (for AWD)

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; DRIVE SHAFT / PROPELLER SHAFT: PROPELLER SHAFT ASSEMBLY: INSTALLATION+

52. INSTALL FRONT EXHAUST PIPE ASSEMBLY

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

53. INSTALL NO. 1 FLOOR UNDER COVER (w/ Cover)

Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; A25A-FKS (FUEL): FUEL TANK (w/ Canister Pump Module): INSTALLATION+

54. INSTALL FRONT FLOOR COVER RH (w/ Cover)

Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; A25A-FKS (FUEL): FUEL TANK (w/ Canister Pump Module): INSTALLATION+

55. INSTALL NO. 2 FLOOR UNDER COVER (w/ Cover)

Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; A25A-FKS (FUEL): FUEL TANK (w/ Canister Pump Module): INSTALLATION+

56. INSTALL FRONT FLOOR COVER LH (w/ Cover)

Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; A25A-FKS (FUEL): FUEL TANK (w/ Canister Pump Module): INSTALLATION+

57. INSTALL NO. 5 WATER BY-PASS HOSE

(a) Install the No. 5 water by-pass hose to the radiator assembly and No. 3 water by-pass pipe, and slide the 2 clips to secure it.

NOTICE:

  • Align the direction of the claw on the clip with the paint mark on the hose.
  • Make sure the No. 5 water by-pass hose is securely inserted to the stopper.

*a

View A

*b

View B

*c

360°

*d

120°

*e

Paint Mark

*f

Upper Side

*g

Front Side

*h

Rear Side

*i

2 to 7 mm (0.0787 to 0.276 in.)

*j

2 to 5 mm (0.0787 to 0.197 in.)

58. CONNECT WIRE HARNESS

(a) Connect the wire harness to the vehicle body with the bolt.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(b) Attach the clamp.

(c) Attach the claw to install the wire harness to the engine room relay block and junction block assembly.

(d) Connect the 5 connectors to the engine room relay block and junction block assembly.

(e) Install the nut to the engine room relay block and junction block assembly.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(f) Attach the 3 claws and install the No. 2 relay block cover.

59. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE SUB-ASSEMBLY

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; HEATING / AIR CONDITIONING: COMPRESSOR (for A25A-FKS): INSTALLATION+

60. CONNECT SUCTION HOSE SUB-ASSEMBLY

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; HEATING / AIR CONDITIONING: COMPRESSOR (for A25A-FKS): INSTALLATION+

61. CONNECT NO. 2 RADIATOR HOSE

(a) Connect the No. 2 radiator hose to the radiator assembly and slide the clip to secure it.

NOTICE:

  • Align the direction of the claw on the clip with the paint mark on the hose.
  • Make sure the No. 2 radiator hose is securely inserted to the stopper.

*a

View A

*b

120°

*c

Paint Mark

*d

Upper Side

*e

RH Side

*f

2 to 5 mm (0.0787 to 0.197 in.)

62. CONNECT NO. 1 RADIATOR HOSE

(a) Connect the No. 1 radiator hose to the water outlet and slide the clip to secure it.

NOTICE:

  • Align the direction of the claw on the clip with the paint mark on the hose.
  • Make sure the No. 1 radiator hose is securely inserted to the stopper.

*a

View A

*b

90°

*c

Paint Mark

*d

Upper Side

*e

Front Side

*f

2 to 7 mm (0.0787 to 0.276 in.)

63. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Connect the fuel tube sub-assembly.

(1) Connect the fuel tube sub-assembly to the fuel pipe.

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (FUEL): FUEL SYSTEM: PRECAUTION

(b) Install the No. 1 fuel pipe clamp to the fuel tube connector.

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (FUEL): FUEL SYSTEM: PRECAUTION

64. CONNECT OUTLET HEATER WATER HOSE

(a) Align the protrusion of the No. 2 water by-pass pipe sub-assembly with the cutout in the outlet heater hose connector and securely insert the outlet heater water hose connector to the stopper of the pipe.

*a

Protrusion

*b

Cutout

(b) Push in the retainer.

*a

Retainer

Push

Push in

(c) Check that the No. 2 water by-pass pipe sub-assembly and outlet heater water hose connector are securely connected by pulling on them.

65. CONNECT INLET HEATER WATER HOSE

(a) Align the protrusions of the inlet heater water hose connector with the cutouts in the flow shutting valve (water by-pass hose assembly) and securely insert the inlet heater water hose connector to the stopper of the pipe.

*a

Protrusion

*b

Cutout

(b) Push in the retainer.

*a

Retainer

Push

Push in

(c) Check that the flow shutting valve (water by-pass hose assembly) and inlet heater water hose connector are securely connected by pulling on them.

66. CONNECT NO. 1 VACUUM HOSE CONNECTOR

Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; BRAKE SYSTEM (OTHER): VACUUM PUMP (for A25A-FKS): INSTALLATION+

67. CONNECT UNION TO CHECK VALVE HOSE

(a) Connect the union to check valve hose to the vacuum pump assembly and slide the clip to secure it.

68. CONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Connect the No. 1 fuel vapor feed hose to the purge VSV and slide the clip to secure it.

69. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Connect the transmission control cable assembly to the No. 1 transmission control cable bracket with a new clip.

(b) Connect the transmission control cable assembly to the transmission control shaft lever as shown in the illustration.

NOTICE:

Before installing the transmission control cable assembly, check that the park/neutral position switch assembly and shift lever are in N.

*a

Correct

*b

Incorrect

70. CONNECT NO. 3 ENGINE WIRE

(a) Connect the No. 3 engine wire to the automatic transaxle assembly with the bolt.

Torque:

20 N·m {204 kgf·cm, 15 ft·lbf}

(b) Attach the clamp to the bracket.

71. INSTALL BATTERY CLAMP SUB-ASSEMBLY

(a) Install the battery clamp sub-assembly with the 3 bolts.

Torque:

18.5 N·m {189 kgf·cm, 14 ft·lbf}

(b) Attach the 2 claws and connect the engine room main wire to the No. 2 engine wire.

*1

Engine Room Main Wire

*2

No. 2 Engine Wire

*3

Positive (+) Battery Terminal

(c) Connect the engine room main wire and No. 2 engine wire to the positive (+) battery terminal with the nut.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

(d) Attach the 2 clamps and connect the engine room main wire and No. 2 engine wire to the battery clamp sub-assembly.

(e) Attach the 2 clamps to the battery clamp sub-assembly.

72. INSTALL BATTERY

Click here 2019 - 2023 MY RAV4 [11/2018 - 10/2023]; MAINTENANCE: A25A-FKS BATTERY: INSTALLATION+

73. INSTALL ECM

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE CONTROL): ECM: INSTALLATION+

74. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE

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

75. INSTALL INLET AIR CLEANER ASSEMBLY

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

76. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

(a) Attach the 3 clips to install the No. 1 engine cover sub-assembly.

NOTICE:

  • Securely attach the clips.
  • If the clips are forcibly attached or struck with an object, they may be damaged.

77. INSPECT VACUUM HOSES

(a) Inspect the vacuum hoses.

*A

for 2WD

*B

for AWD

78. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

Click here 2021 MY RAV4 RAV4 HV [08/2020 - 12/2021]; INTRODUCTION: REPAIR INSTRUCTION: INITIALIZATION

79. INSPECT SHIFT LEVER POSITION

  • for 2WD:

    Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; UB80E (AUTOMATIC TRANSMISSION / TRANSAXLE): SHIFT LEVER: ON-VEHICLE INSPECTION+

  • for AWD:

    Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; UB80F (AUTOMATIC TRANSMISSION / TRANSAXLE): SHIFT LEVER: ON-VEHICLE INSPECTION+

80. ADJUST SHIFT LEVER POSITION

  • for 2WD:

    Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; UB80E (AUTOMATIC TRANSMISSION / TRANSAXLE): TRANSMISSION CONTROL CABLE: ADJUSTMENT+

  • for AWD:

    Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; UB80F (AUTOMATIC TRANSMISSION / TRANSAXLE): TRANSMISSION CONTROL CABLE: ADJUSTMENT+

81. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

Click here 2019 - 2024 MY RAV4 RAV4 HV [02/2019 -        ]; HEATING / AIR CONDITIONING: REFRIGERANT (for HFO-1234yf(R1234yf)): REPLACEMENT+

82. ADD ENGINE OIL

Click here 2021 MY RAV4 [08/2020 - 12/2021]; MAINTENANCE: A25A-FKS OIL AND OIL FILTER: REPLACEMENT+

83. ADD SPECIFIED AMOUNT OF AUTOMATIC TRANSAXLE FLUID

  • for 2WD:

    Click here 2020 - 2021 MY RAV4 [10/2019 - 12/2021]; UB80E (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE FLUID: ADJUSTMENT

  • for AWD:

    Click here 2020 - 2021 MY RAV4 [10/2019 - 12/2021]; UB80F (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE FLUID: ADJUSTMENT

84. ADD TRANSFER OIL (for AWD)

  • GF1A:

    Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; MAINTENANCE: GF1A TRANSFER OIL: REPLACEMENT+

  • GF2A:

    Click here 2020 - 2024 MY RAV4 [10/2019 -        ]; MAINTENANCE: GF2A TRANSFER OIL: REPLACEMENT+

85. ADD ENGINE COOLANT

Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; MAINTENANCE: A25A-FKS COOLANT: REPLACEMENT+

86. ADJUST AUTOMATIC TRANSAXLE FLUID

  • for 2WD:

    Click here 2020 - 2021 MY RAV4 [10/2019 - 12/2021]; UB80E (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE FLUID: ADJUSTMENT

  • for AWD:

    Click here 2020 - 2021 MY RAV4 [10/2019 - 12/2021]; UB80F (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE FLUID: ADJUSTMENT

87. WARM UP ENGINE

Click here 2019 - 2024 MY RAV4 RAV4 HV [02/2019 -        ]; HEATING / AIR CONDITIONING: REFRIGERANT (for HFO-1234yf(R1234yf)): REPLACEMENT+

88. INSPECT FOR ENGINE OIL LEAK

Click here 2021 MY RAV4 [08/2020 - 12/2021]; MAINTENANCE: A25A-FKS OIL AND OIL FILTER: REPLACEMENT+

89. INSPECT FOR COOLANT LEAK

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

90. INSPECT FOR REFRIGERANT LEAK

Click here 2019 - 2024 MY RAV4 RAV4 HV [02/2019 -        ]; HEATING / AIR CONDITIONING: REFRIGERANT (for HFO-1234yf(R1234yf)): REPLACEMENT+

91. INSPECT FOR FUEL LEAK

Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; A25A-FKS (FUEL): FUEL SYSTEM: ON-VEHICLE INSPECTION+

92. INSPECT FOR EXHAUST GAS LEAK

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (INTAKE / EXHAUST): EXHAUST PIPE: INSTALLATION+

93. CHECK ENGINE OIL LEVEL

Click here 2021 - 2023 MY RAV4 [08/2020 - 10/2023]; A25A-FKS (LUBRICATION): LUBRICATION SYSTEM: ON-VEHICLE INSPECTION+

94. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR

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

95. INSTALL FRONT LOWER BUMPER ABSORBER

(a) Attach the 2 claws to install the front lower bumper absorber.

(b) Install the 5 bolts.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

96. INSTALL FRONT BUMPER ASSEMBLY

  • for Off Road Package:

    Click here 2021 MY RAV4 RAV4 HV [08/2020 - 12/2021]; EXTERIOR PANELS / TRIM: FRONT BUMPER (for Off Road Package): INSTALLATION

  • except Off Road Package:

    Click here 2021 MY RAV4 RAV4 HV [08/2020 - 12/2021]; EXTERIOR PANELS / TRIM: FRONT BUMPER (except Off Road Package): INSTALLATION

97. INSTALL FRONT FENDER APRON SEAL LH

(a) Install the front fender apron seal LH with the 2 bolts and clip.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

Bolt

Clip

98. INSTALL FRONT FENDER APRON SEAL RH

(a) Install the front fender apron seal RH with the 2 bolts and clip.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

Bolt

Clip

99. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY

(a) Install the No. 2 engine under cover assembly with the 2 bolts, 2 screws and 6 clips.

Torque:

Bolt :

7.5 N·m {76 kgf·cm, 66 in·lbf}

Bolt

Screw

100. INSTALL NO. 1 ENGINE UNDER COVER

(a) Attach the guide and install the No. 1 engine under cover.

(b) Install the 2 bolts and 10 screws. (Short Type Front Fender Front Splash Shield)

Torque:

Bolt :

7.5 N·m {76 kgf·cm, 66 in·lbf}

(c) Install the 2 bolts and 8 screws. (Long Type Front Fender Front Splash Shield)

Torque:

Bolt :

7.5 N·m {76 kgf·cm, 66 in·lbf}

*a

Short Type Front Fender Front Splash Shield

-

-

Bolt

Screw

101. INSTALL FRONT FENDER FRONT SPLASH SHIELD LH

(a) for Short Type:

(1) Attach the clip to install the front fender front splash shield LH.

(2) Install the 3 screws.

(b) for Long Type:

(1) Attach the clip to install the front fender front splash shield LH.

(2) Install the 4 screws.

102. INSTALL FRONT FENDER FRONT SPLASH SHIELD RH

(a) for Short Type:

(1) Attach the clip to install the front fender front splash shield RH.

(2) Install the 3 screws.

(b) for Long Type:

(1) Attach the clip to install the front fender front splash shield RH.

(2) Install the 4 screws.

103. INSTALL FRONT WHEELS

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; MAINTENANCE: TIRE AND WHEEL: INSTALLATION+

104. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

105. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

Click here 2021 MY RAV4 RAV4 HV [08/2020 - 12/2021]; ALIGNMENT / HANDLING DIAGNOSIS: FRONT WHEEL ALIGNMENT: ADJUSTMENT

106. INSPECT THROTTLE BODY WITH MOTOR ASSEMBLY

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE CONTROL): THROTTLE BODY: ON-VEHICLE INSPECTION+

107. INSPECT IGNITION TIMING

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE: ON-VEHICLE INSPECTION+

108. INSPECT ENGINE IDLE SPEED

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE: ON-VEHICLE INSPECTION+

109. INSPECT CO/HC

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE: ON-VEHICLE INSPECTION+

110. CHECK SPEED SENSOR SIGNAL

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: ELECTRONICALLY CONTROLLED BRAKE SYSTEM (w/ Vacuum Brake Booster): TEST MODE PROCEDURE