A25A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL; 2023 MY RAV4 [10/2022

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM1000000026SYN
Model Year Start: 2023	Model: RAV4	Prod Date Range: [10/2022 - 10/2023]
Title: A25A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL; 2023 MY RAV4 [10/2022 - 10/2023]

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 engine assembly removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
*: When performing learning using the Techstream. Click here
Battery terminal is disconnected/reconnected	Drive the vehicle until stop and start control is permitted (approximately 5 to 60 minutes)	Stop and start system
	Perform steering sensor zero point calibration	Lane control system
		Parking support brake system (for Gasoline model)*
		Pre-collision system
	Reset back door close position	Power back door system (for Gasoline model)
	Back door lock initialization	Power door lock control system
Replacement of ECM	Perform Vehicle Identification Number (VIN) registration	DTC P063051 is output
	Code registration	Engine start function	w/ Smart Key System: w/o Smart Key System:
	for UB80E: If transaxle compensation code read from ECM Perform reset memory Transfer transaxle compensation code Perform road test to allow ECM to learn	Large shift shock Deterioration of fuel efficiency	for Initialization: for Registration:
	for UB80F: If transaxle compensation code read from ECM Perform reset memory Transfer transaxle compensation code Perform road test to allow ECM to learn	Large shift shock Deterioration of fuel efficiency	for Initialization: for Registration:
Replacement of engine assembly Gas leak from exhaust system is repaired	Inspection after repair	Poor idle, etc. Engine start function, etc.
Replacement of automatic transaxle assembly	for UB80E: Reset memory Input transaxle compensation code into ECM Perform road test to allow ECM to learn	Large shift shock Deterioration of fuel efficiency	for Initialization: for Registration:
Replacement of automatic transaxle assembly	for UB80F: Reset memory Input transaxle compensation code into ECM Perform road test to allow ECM to learn	Large shift shock Deterioration of fuel efficiency	for Initialization: for Registration:
Automatic transaxle fluid	ATF thermal degradation estimate reset	The value of the Data List item "ATF Thermal Degradation Estimate" is not estimated correctly	for UB60E: for UB60F:
Suspension, tires, etc. (The vehicle height changes because of suspension or tire replacement)	Television camera assembly optical axis (Back camera position setting)	Parking assist monitor system
	Parking assist ECU initialization	Panoramic view monitor system (for Gasoline model)
Front wheel alignment adjustment	Perform reset memory Perform acceleration sensor zero point calibration and store system information memorization.	VSC is disabled or malfunctions DTCs are output Slip indicator light illuminates ABS warning light illuminates
Front bumper assembly (Including removal and installation)	Front television camera view adjustment	Panoramic view monitor system (for Gasoline model)

NOTICE:

After the ignition switch is turned off, the audio and visual system records various types of memory and settings. As a result, after turning the ignition switch off, make sure to wait at least 2 minutes before disconnecting the cable from the negative (-) auxiliary battery terminal.
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

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.

*a	An Object Exceeding Weight Limit of Engine Lifter

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

PROCEDURE

1. PRECAUTION

NOTICE:

After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

Click here

2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

Click here

3. DISCHARGE FUEL SYSTEM PRESSURE

Click here

4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:

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

Click here

5. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

6. SECURE STEERING WHEEL

Click here

7. REMOVE FRONT WHEELS

Click here

8. REMOVE FRONT FENDER FRONT SPLASH SHIELD LH

(a) for Short Type:

(1) Remove the 3 screws.

(2) Detach the clip and remove the front fender front splash shield LH.

(b) for Long Type:

(1) Remove the 4 screws.

(2) Detach the clip and remove the front fender front splash shield LH.

9. REMOVE FRONT FENDER FRONT SPLASH SHIELD RH

(a) for Short Type:

(1) Remove the 3 screws.

(2) Detach the clip and remove the front fender front splash shield RH.

(b) for Long Type:

(1) Remove the 4 screws.

(2) Detach the clip and remove the front fender front splash shield RH.

10. REMOVE NO. 1 ENGINE UNDER COVER

(a) Remove the 2 bolts and 10 screws. (Short Type Front Fender Front Splash Shield)

(b) Remove the 2 bolts and 8 screws. (Long Type Front Fender Front Splash Shield)

*a	Short Type Front Fender Front Splash Shield	-	-
	Bolt		Screw

11. REMOVE NO. 2 ENGINE UNDER COVER ASSEMBLY

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

	Bolt
	Screw

12. REMOVE FRONT FENDER APRON SEAL LH

(a) Remove the 2 bolts, clip and front fender apron seal LH.

	Bolt
	Clip

13. REMOVE FRONT FENDER APRON SEAL RH

(a) Remove the 2 bolts, clip and front fender apron seal RH.

	Bolt
	Clip

14. REMOVE FRONT BUMPER ASSEMBLY

for Off Road Package:
Click here
except Off Road Package:
Click here

15. REMOVE FRONT LOWER BUMPER ABSORBER

(a) Remove the 5 bolts.

(b) Detach the 2 claws and remove the front lower bumper absorber.

16. DRAIN ENGINE COOLANT

Click here

17. DRAIN ENGINE OIL

Click here

18. DRAIN AUTOMATIC TRANSAXLE FLUID

for 2WD:
Click here
for AWD:
Click here

19. DRAIN TRANSFER OIL (for AWD)

GF1A:
Click here
GF2A:
Click here

20. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

(a) Lift the front of the No. 1 engine cover sub-assembly to detach the 2 clips, and then lift the rear of the No. 1 engine cover sub-assembly to detach the clip and remove the No. 1 engine cover sub-assembly.

NOTICE:

Attempting to detach both front and rear clips at the same time may cause the No. 1 engine cover sub-assembly to break.

21. REMOVE INLET AIR CLEANER ASSEMBLY

Click here

22. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE

Click here

23. REMOVE ECM

Click here

24. REMOVE BATTERY

Click here

25. REMOVE BATTERY CLAMP SUB-ASSEMBLY

(a) Detach the 2 clamps from the battery clamp sub-assembly.

(b) Detach the 2 clamps and disconnect the engine room main wire and No. 2 engine wire from the battery clamp sub-assembly.

*1	No. 2 Engine Wire
*2	Engine Room Main Wire
*3	Positive (+) Battery Terminal

(c) Remove the nut and disconnect the engine room main wire and No. 2 engine wire from the positive (+) battery terminal.

(d) Detach the 2 claws and disconnect the engine room main wire from the No. 2 engine wire.

(e) Remove the 3 bolts and battery clamp sub-assembly.

26. DISCONNECT NO. 3 ENGINE WIRE

(a) Detach the clamp from the bracket.

(b) Remove the bolt and disconnect the No. 3 engine wire from the automatic transaxle assembly.

27. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) While disengaging the clip as shown in the illustration, disconnect the transmission control cable assembly from the transmission control shaft lever together with the clip.

*a	Clip
*b	45° to 60°

(b) Remove the clip and disconnect the transmission control cable assembly from the No. 1 transmission control cable bracket.

28. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Slide the clip and disconnect the No. 1 fuel vapor feed hose from the Purge VSV.

29. DISCONNECT UNION TO CHECK VALVE HOSE

(a) Slide the clip and disconnect the union to check valve hose from the vacuum pump assembly.

30. DISCONNECT NO. 1 VACUUM HOSE CONNECTOR

Click here

31. DISCONNECT INLET HEATER WATER HOSE

(a) Pull out the retainer to detach the lock claws and pull off the inlet heater water hose.

*a	Retainer
	Pull out
	Pull off

(b) Check that there is no foreign matter on the sealing surfaces of the disconnected water lines. Clean them if necessary.

(c) Cover the disconnected flow shutting valve (water by-pass hose assembly) and inlet heater water hose connector with plastic bags to prevent damage and contamination.

32. DISCONNECT OUTLET HEATER WATER HOSE

(a) Pull out the retainer to detach the lock claws and pull off the outlet heater water hose.

*a	Retainer
	Pull out
	Pull off

(b) Check that there is no foreign matter on the sealing surfaces of the disconnected water lines. Clean them if necessary.

(c) Cover the disconnected No. 2 water by-pass pipe sub-assembly and outlet heater water hose connector with plastic bags to prevent damage and contamination.

33. DISCONNECT FUEL TUBE SUB-ASSEMBLY

(a) Remove the No. 1 fuel pipe clamp from the fuel tube connector.

Click here

(b) Disconnect the fuel tube sub-assembly.

(1) Disconnect the fuel tube sub-assembly from the fuel pipe.

Click here

34. DISCONNECT NO. 1 RADIATOR HOSE

(a) Remove the clamp to disconnect the No. 1 radiator hose from the No. 1 radiator bracket.

(b) Slide the clip and disconnect the No. 1 radiator hose from the water outlet.

35. DISCONNECT NO. 2 RADIATOR HOSE

(a) Detach the clamp and disconnect the No. 2 radiator hose from the fan with motor assembly.

(b) Slide the clip and disconnect the No. 2 radiator hose from the radiator assembly.

36. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

Click here

37. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE SUB-ASSEMBLY

Click here

38. DISCONNECT WIRE HARNESS

HINT:

After disconnecting the wire harness, secure it with tape or equivalent to keep it out of the way.

(a) Detach the 3 claws and remove the No. 2 relay block cover.

(b) Remove the nut from the engine room relay block and junction block assembly.

(d) Using a screwdriver, detach the claw and disconnect the wire harness from the engine room relay block and junction block assembly.

(e) Detach the clamp.

(f) Remove the bolt and disconnect the wire harness from the vehicle body.

39. REMOVE NO. 5 WATER BY-PASS HOSE

(a) Slide the 2 clips and remove the No. 5 water by-pass hose from the radiator assembly and No. 3 water by-pass pipe.

40. REMOVE FRONT FLOOR COVER LH (w/ Cover)

Click here

41. REMOVE NO. 2 FLOOR UNDER COVER (w/ Cover)

Click here

42. REMOVE FRONT FLOOR COVER RH (w/ Cover)

Click here

43. REMOVE NO. 1 FLOOR UNDER COVER (w/ Cover)

Click here

44. REMOVE FRONT EXHAUST PIPE ASSEMBLY

Click here

45. REMOVE LOWER NO. 1 FRONT FLOOR HEAT INSULATOR (for AWD)

Click here

46. REMOVE PROPELLER SHAFT ASSEMBLY (for AWD)

Click here

47. REMOVE FRONT AXLE SHAFT NUT LH

Click here

48. REMOVE FRONT AXLE SHAFT NUT RH

HINT: