A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: INSTALLATION; 2022 - 2024 MY RAV4 [12/2021

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM1000000021JN3
Model Year Start: 2022	Model: RAV4	Prod Date Range: [12/2021 - ]
Title: A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: INSTALLATION; 2022 - 2024 MY RAV4 [12/2021 - ]

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

PROCEDURE

1. INSTALL NO. 2 VACUUM SWITCHING VALVE BRACKET

(a) Using an 8 mm socket wrench, install the No. 2 vacuum switching valve bracket to the cylinder head sub-assembly with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

2. INSTALL PURGE VALVE (PURGE VSV)

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3. 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}

4. 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.

5. INSTALL IGNITION COIL ASSEMBLY

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6. INSTALL FUEL INJECTOR SEAL

Click here

7. INSTALL DIRECT FUEL INJECTOR ASSEMBLY

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8. INSTALL FUEL DELIVERY PIPE

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9. INSTALL PORT FUEL INJECTOR ASSEMBLY

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10. INSTALL NO. 5 ENGINE WIRE

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11. INSTALL INJECTOR VIBRATION INSULATOR

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12. INSTALL NO. 1 DELIVERY PIPE SPACER

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13. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

Click here

14. 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}

15. 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.

16. 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.

17. INSTALL NO. 7 WATER BY-PASS HOSE

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

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

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

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

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21. 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.
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)

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

(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)

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

22. CONNECT FUEL TUBE SUB-ASSEMBLY

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23. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET

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24. INSTALL INTAKE MANIFOLD

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25. 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}

26. 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}

27. SET EGR VALVE ASSEMBLY

(a) Set the EGR valve assembly to the camshaft housing.

HINT:

At this time, do not install the parts with bolts.

28. 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.

29. INSTALL EGR COOLER ASSEMBLY

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

NOTICE:

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

Claw

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

NOTICE:

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

(1) Temporarily install the EGR cooler assembly to the cylinder head sub-assembly and EGR valve assembly with the 2 bolts and 3 nuts.

	Bolt
	Nut

(2) Tighten the 2 bolts and 3 nuts in the order shown in the illustration.

Torque:

24 N·m {245 kgf·cm, 18 ft·lbf}

(d) Type B:

(1) Temporarily install the EGR cooler assembly to the cylinder head sub-assembly and EGR valve assembly with the 3 bolts and 2 nuts.

	Bolt
	Nut

(2) Tighten the 3 bolts and 2 nuts in the order shown in the illustration.

Torque:

24 N·m {245 kgf·cm, 18 ft·lbf}

(e) Connect the No. 3 water by-pass hose to the EGR cooler assembly.

(f) Connect the No. 4 water by-pass hose to the EGR cooler assembly.

30. INSTALL EGR VALVE ASSEMBLY

(a) Using an 8 mm socket wrench, install the EGR valve assembly with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

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

31. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

(a) Using an 8 mm socket wrench, install the No. 1 EGR pipe sub-assembly, a new EGR inlet gasket and a new EGR valve adapter gasket with the 4 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

32. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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33. INSTALL EXHAUST MANIFOLD

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34. INSTALL MANIFOLD STAY

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35. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

(a) for Type A:

(1) Install the No. 1 exhaust manifold heat insulator to the exhaust manifold with the 3 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) for Type B:

(1) 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}

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

(a) 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	View A
*b	90°
*c	Upper Side
*d	RH Side
*e	2 to 7 mm (0.0787 to 0.276 in.)

(b) Install the water hose clamp bracket with the 2 bolts.

Torque:

13 N·m {133 kgf·cm, 10 ft·lbf}

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

37. 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.

38. INSTALL NO. 3 TIMING CHAIN COVER

(a) Using an 8 mm socket wrench, install the No. 3 timing chain cover and plate washer to the No. 2 timing chain cover assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

39. INSTALL TIMING GEAR COVER INSULATOR

(a) Using an 8 mm socket wrench, install the timing gear cover insulator and plate washer to the No. 2 timing chain cover assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

40. INSTALL NO. 2 TIMING CHAIN COVER INSULATOR

(a) Install the No. 2 timing chain cover insulator to the V-ribbed belt tensioner assembly.

41. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

NOTICE:

Do not apply or add any oil or grease to the belt tensioner to prevent abnormal noises from the belt tensioner pulley, belt squealing, etc.
Do not allow oil or grease to adhere to the moving parts of the belt tensioner, as this may cause malfunctions.

(a) Install the V-ribbed belt tensioner assembly to the No. 2 timing chain cover assembly with the 2 bolts.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

42. INSTALL NO. 2 ENGINE COVER

(a) Install the No. 2 engine cover to the No. 2 timing chain cover assembly with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

43. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

(a) for Type A:

(1) 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}

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

	Bolt
	Nut

Torque:

24.5 N·m {250 kgf·cm, 18 ft·lbf}

HINT:

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

(b) for Type B:

(1) Install the compressor assembly with pulley with the 4 bolts.

Torque:

24.5 N·m {250 kgf·cm, 18 ft·lbf}

HINT:

Tighten the bolts in the order shown in the illustration.

44. INSTALL GENERATOR ASSEMBLY

for 100 A, 130 A Type:
Click here
for 150 A Type:
Click here
for VALEO Made:
Click here

45. INSTALL V-RIBBED BELT

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46. 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}