A25A-FXS (EMISSION CONTROL): EGR COOLER: INSTALLATION; 2022 - 2024 MY RAV4 HV [12/2021

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM1000000021JTQ
Model Year Start: 2022	Model: RAV4 HV	Prod Date Range: [12/2021 - ]
Title: A25A-FXS (EMISSION CONTROL): EGR COOLER: INSTALLATION; 2022 - 2024 MY RAV4 HV [12/2021 - ]

INSTALLATION

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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1. INSTALL EGR COOLER ASSEMBLY

(a) Using an 8 mm socket wrench, loosen the 4 bolts of the No. 1 EGR pipe sub-assembly.

HINT:

As the bolts of the No. 1 EGR pipe sub-assembly are only to be loosened, it is not necessary to replace the EGR inlet gasket and EGR valve adapter gasket.
If the No. 1 EGR pipe sub-assembly is removed, it is necessary to replace the EGR inlet gasket and EGR valve adapter gasket with new ones.

(b) Using an 8 mm socket wrench, loosen the 2 bolts of the EGR valve assembly.

NOTICE:

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

Claw

(d) 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.

(e) Type A:

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

(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}

*a	Bolt or Nut

(f) Type B:

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

(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}

(g) Connect the No. 3 water by-pass hose and No. 4 water by-pass hose to the EGR cooler assembly and slide the 2 clips to secure them.

(h) Using an 8 mm socket wrench, tighten the 2 bolts of the EGR valve assembly.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(i) Using an 8 mm socket wrench, tighten the 4 bolts of the No. 1 EGR pipe sub-assembly.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

2. INSTALL HYBRID MOTOR CONTROL INVERTER ASSEMBLY

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3. ADD ENGINE COOLANT (for Engine)

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4. INSPECT FOR COOLANT LEAK (for Engine)

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5. INSPECT FOR EXHAUST GAS LEAK

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