Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM1000000021JUX
Model Year Start: 2022 Model: RAV4 Prod Date Range: [12/2021 -           ]
Title: A25A-FKS (EMISSION CONTROL): EGR COOLER: REMOVAL; 2022 - 2024 MY RAV4 [12/2021 -        ]

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 EGR cooler assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedures

Effect/Inoperative Function when Necessary Procedure not Performed

Link

Gas leak from exhaust system is repaired

Inspection After Repair
  • Poor idle, etc.
  • Engine start function, etc.

2022 - 2024 MY RAV4 RAV4 HV [12/2021 -        ]; A25A-FKS (ENGINE CONTROL): SFI SYSTEM: INITIALIZATION

NOTICE:

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. DRAIN ENGINE COOLANT

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

2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

Click here 2022 MY RAV4 [12/2021 - 10/2022]; A25A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+ 2023 MY RAV4 [10/2022 - 10/2023]; A25A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+ 2024 MY RAV4 [10/2023 -        ]; A25A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

3. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

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

4. REMOVE EGR COOLER ASSEMBLY

(a) Slide the 2 clips and disconnect the No. 3 water by-pass hose and No. 4 water by-pass hose from the EGR cooler assembly.

*1

No. 3 Water By-pass Hose

*2

No. 4 Water By-pass Hose

(b) Type A:

(1) Remove the 3 bolts, 2 nuts and EGR cooler assembly from the cylinder head sub-assembly and EGR valve assembly.

*a

Bolt or Nut

(c) Type B:

(1) Remove the 2 bolts, 3 nuts and EGR cooler assembly from the cylinder head sub-assembly and EGR valve assembly.

(d) Remove the EGR valve gasket from the EGR cooler assembly.

*1

EGR Valve Gasket

*2

EGR Cooler Gasket

(e) Remove the EGR cooler gasket from the EGR cooler assembly.