- Replacement of engine assembly
- Gas leak from exhaust system is repaired
- Replacement of air fuel ratio sensor (sensor 2)
| Last Modified: 05-08-2025 | 6.11:8.1.0 | Doc ID: RM1000000026TKX |
| Model Year Start: 2023 | Model: RAV4 HV | Prod Date Range: [10/2022 - 10/2023] |
| Title: A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL; 2023 MY RAV4 HV [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
|
|||
|
Auxiliary battery terminal is disconnected/reconnected |
Perform steering sensor zero point calibration |
Lane control system |
|
|
Parking support brake system (for HV model)* |
|||
|
Pre-collision system |
|||
|
Reset back door close position |
Power back door system (for HV model) |
|
|
|
Back door lock initialization |
Power door lock control system |
|
|
|
Replacement of ECM |
Perform Vehicle Identification Number (VIN) registration |
DTC P063051 is output |
|
|
Grille shutter switch specification infomation |
Vehicle control history (RoB) [X260E] is stored |
|
|
|
|
Inspection after repair |
|
|
|
Replacement of inverter with converter assembly |
Resolver learning |
|
|
|
Replacement of hybrid vehicle transaxle assembly |
|
||
|
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 HV model) |
|
|
|
Front wheel alignment adjustment |
|
|
|
|
Front bumper assembly (Including removal and installation) |
Front television camera view adjustment |
Panoramic view monitor system (for HV 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.
- When the cable is disconnected from the negative (-) auxiliary battery terminal and the security lock setting has been enabled, multi-display operations will be disabled upon next startup unless the password is entered. Be sure to check the security lock setting 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
![2019 - 2025 MY RAV4 RAV4 HV [11/2018 - ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION](/t3Portal/stylegraphics/info.gif)
PROCEDURE
1. PRECAUTION
NOTICE:
After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.
Click here
2. REMOVE DECK BOARD ASSEMBLY
Click here
3. REMOVE REAR NO. 2 FLOOR BOARD
Click here
4. REMOVE BATTERY HOLE COVER
Click here
5. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL
Click here
6. REMOVE BATTERY SERVICE HOLE COVER
Click here
7. REMOVE SERVICE PLUG GRIP
Click here
8. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM
Click here
9. DISCHARGE FUEL SYSTEM PRESSURE
Click here
10. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD
11. SECURE STEERING WHEEL
Click here
12. REMOVE FRONT WHEELS
Click here
13. 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.
14. 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.
15. REMOVE NO. 1 ENGINE UNDER COVER
(a) for Type A:
(1) Remove the 2 bolts and 6 screws.
(2) Detach the guide and remove the No. 1 engine under cover.
|
Bolt |
|
Screw |
(b) for Type B:
(1) Remove the 2 bolts and 10 screws. (Short Type Front Fender Front Splash Shield)
(2) Remove the 2 bolts and 8 screws. (Long Type Front Fender Front Splash Shield)
(3) Detach the guide and remove the No. 1 engine under cover.
|
*a |
Short Type Front Fender Front Splash Shield |
- |
- |
|
|
Bolt |
|
Screw |
16. 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 |
|
Clip |
17. REMOVE FRONT FENDER APRON SEAL LH
(a) Remove the 2 bolts, clip and front fender apron seal LH.
|
|
Bolt |
|
|
Clip |
18. REMOVE FRONT FENDER APRON SEAL RH
(a) Remove the 2 bolts, clip and front fender apron seal RH.
|
|
Bolt |
|
|
Clip |
19. REMOVE FRONT BUMPER ASSEMBLY
Click here
20. REMOVE HEADLIGHT ASSEMBLY LH
-
for Triple Beam Headlight:
Click here
-
for Single Beam Headlight:
Click here
21. REMOVE FRONT LOWER BUMPER ABSORBER
|
(a) Remove the clip. |
|
(b) Detach the claws and remove the front lower bumper absorber.
22. REMOVE FRONT BUMPER NO. 2 REINFORCEMENT
Click here
23. DRAIN ENGINE COOLANT (for Engine)
Click here
24. DRAIN ENGINE OIL
Click here
25. DRAIN HYBRID TRANSAXLE FLUID
Click here
26. 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. |
|
27. REMOVE INLET AIR CLEANER ASSEMBLY
Click here
28. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE
Click here
29. REMOVE INVERTER WITH CONVERTER ASSEMBLY
Click here
30. REMOVE INVERTER RESERVE TANK ASSEMBLY
(a) Remove the 2 bolts.
|
*1 |
No. 2 Inverter Cooling Hose |
|
*2 |
No. 5 Inverter Cooling Hose |
|
*a |
Pin |
|
*b |
Grommet |
|
|
Bolt |
|
|
Clip |
(b) Detach the pin and remove the inverter reserve tank assembly.
(c) Slide the 2 clips and disconnect the No. 2 inverter cooling hose and No. 5 inverter cooling hose from the inverter reserve tank assembly.
31. REMOVE NO. 5 WATER BY-PASS HOSE
|
(a) Slide the 2 clips and remove the No. 5 water by-pass hose from the No. 3 water by-pass pipe and radiator assembly. |
|
32. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE
|
(a) Detach the clamp. |
|
(b) Disconnect the No. 1 fuel vapor feed hose from the purge VSV.
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 OUTLET HEATER WATER HOSE
(a) Pull out the retainer to detach the lock claws and pull off the outlet heater water hose from the No. 2 water by-pass pipe sub-assembly.
|
*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.
35. DISCONNECT INLET HEATER WATER HOSE
(a) Pull out the retainer to detach the lock claws and pull off the inlet heater water hose from the flow shutting valve (water by-pass hose assembly).
|
*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.
36. DISCONNECT NO. 1 RADIATOR HOSE
|
(a) Detach the clamp. |
|
(b) Slide the clip and disconnect the No. 1 radiator hose from the water outlet.
37. DISCONNECT NO. 2 RADIATOR HOSE
|
(a) Slide the clip and disconnect the No. 2 radiator hose from the water inlet. |
|
38. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE
Click here
39. DISCONNECT SUCTION HOSE SUB-ASSEMBLY
Click here
40. DISCONNECT NO. 5 INVERTER COOLING HOSE
|
(a) Slide the clip and disconnect the No. 5 inverter cooling hose from the motor cooling cooler. NOTICE:
|
|
41. 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 claws and remove the No. 2 relay block cover. |
|
(b) Remove the nut from the engine room relay block and junction block assembly.
|
|
Nut |
|
|
Connector |
(c) Disconnect the connectors 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 2 bolts and disconnect the ground wires.
42. REMOVE ENGINE UNDER COVER HEAT INSULATOR
|
(a) Remove the 2 clips and engine under cover heat insulator. |
|
43. REMOVE FRONT FLOOR COVER LH
(a) Remove the 2 bolts, 4 screws and clip.
|
|
Bolt |
|
|
Screw |
|
|
Clip |
(b) Detach the clips and remove the front floor cover LH.
44. REMOVE FRONT FLOOR COVER RH
(a) Remove the 2 bolts, 3 screws and clip.
|
|
Bolt |
|
|
Screw |
|
|
Clip |
(b) Detach the clips and remove the front floor cover RH.
45. REMOVE FRONT EXHAUST PIPE ASSEMBLY
Click here
46. REMOVE FRONT AXLE SHAFT NUT LH
Click here
47. REMOVE FRONT AXLE SHAFT NUT RH
HINT:
Use the same procedure described for the LH side.
48. DISCONNECT FRONT SPEED SENSOR LH
Click here
49. DISCONNECT FRONT SPEED SENSOR RH
HINT:
Use the same procedure described for the LH side.
50. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH
Click here
51. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH
HINT:
Use the same procedure described for the LH side.
52. DISCONNECT TIE ROD ASSEMBLY LH
Click here
53. DISCONNECT TIE ROD ASSEMBLY RH
HINT:
Use the same procedure described for the LH side.
54. DISCONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH
Click here
55. DISCONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH
HINT:
Use the same procedure described for the LH side.
56. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
Click here
57. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
Click here
58. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY
Click here
59. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(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.
- To prevent the engine assembly from unexpectedly moving, securely support the engine assembly until it is secured to an engine stand.
(b) Remove the 3 bolts and nut and separate the engine mounting insulator sub-assembly RH from the engine mounting bracket RH.
|
|
Bolt |
|
|
Nut |
|
(c) Remove the 3 bolts and the engine mounting stay LH from the engine mounting insulator sub-assembly LH. |
|
|
(d) Remove the 4 bolts and separate the engine mounting insulator sub-assembly LH from the hybrid vehicle transaxle assembly. |
|
|
*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 |
(e) Remove the 2 bolts (A), 2 bolts (B), 4 nuts and front bumper extension sub-assembly LH and front bumper extension sub-assembly RH from the front frame assembly and vehicle body.
(f) Remove the 2 bolts (C), 4 bolts (D) and rear front suspension member brace LH and rear front suspension member brace RH from the front frame assembly and vehicle body.
(g) Operate the engine lifter and remove the engine assembly with transaxle from the vehicle.
NOTICE:
- Make sure that the engine assembly with transaxle is clear of all wiring and hoses.
- While lowering the engine assembly with transaxle from the vehicle, do not allow it to contact the vehicle.
60. REMOVE FUEL DELIVERY GUARD
|
(a) Remove the bolt and fuel delivery guard from the engine mounting bracket RH. |
|
61. INSTALL ENGINE HANGERS
|
(a) Install the No. 1 engine hanger and No. 2 engine hanger with the 4 bolts as shown in the illustration. Torque: 43 N·m {438 kgf·cm, 32 ft·lbf}
|
|
(b) Using an engine sling device and engine lift, secure the engine assembly with transaxle.
NOTICE:
- Pay attention to the angle of the sling device as the engine assembly or No. 1 engine hanger and No. 2 engine hanger may be damaged or deformed if the angle is incorrect.
- 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.
62. REMOVE FLYWHEEL HOUSING UNDER COVER
|
(a) Remove the flywheel housing under cover from the cylinder block sub-assembly. |
|
63. REMOVE FRONT FRAME ASSEMBLY
Click here
64. REMOVE FRONT ENGINE MOUNTING INSULATOR
HINT:
Perform this procedure only when replacement of the front engine mounting insulator is necessary.
Click here
65. REMOVE WIRING HARNESS CLAMP BRACKET
|
(a) Detach the clamps and disconnect the engine wire. |
|
(b) Remove the bolt and wiring harness clamp bracket.
66. REMOVE REAR ENGINE MOUNTING INSULATOR
HINT:
Perform this procedure only when replacement of the rear engine mounting insulator is necessary.
|
(a) Detach the clamp and disconnect the engine wire. |
|
(b) Remove the bolt and rear engine mounting insulator from the rear engine mounting bracket.
67. REMOVE ENGINE WIRE
(a) Remove the engine wire from the engine assembly.
68. REMOVE HV AIR CONDITIONING WIRE
|
(a) Detach the clamps. |
|
(b) Using a screwdriver, slide the green-colored lock of the connector as shown in the illustration to release it and disconnect the connector.
|
*a |
Green-colored Lock |
|
|
Slide |
CAUTION:
Make sure to wear insulated gloves.
NOTICE:
Insulate the disconnected terminals and connector with insulating tape.
|
(c) Remove the 2 bolts. |
|
(d) Detach the guide to remove the HV air conditioning wire from the hybrid vehicle transaxle assembly.
69. REMOVE STARTER HOLE INSULATOR
Click here
70. REMOVE FLYWHEEL HOUSING SIDE COVER
Click here
71. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY
Click here
72. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY
Click here
73. REMOVE FLYWHEEL SUB-ASSEMBLY
Click here
74. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE
Click here
75. INSTALL ENGINE ASSEMBLY TO ENGINE STAND
(a) Install the engine assembly to an engine stand.
76. 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.
77. REMOVE NO. 1 INVERTER RESERVE TANK BRACKET
|
(a) Remove the bolt and No. 1 inverter reserve tank bracket. |
|
78. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH
HINT:
Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.
|
(a) Disconnect the connector. |
|
(b) Detach the clamps and disconnect the suction pipe sub-assembly and air conditioning tube and accessory assembly.
(c) Disconnect the No. 6 water by-pass hose and detach the clamp.
|
|
No. 6 Water By-pass Hose |
|
|
Bolt |
|
|
Nut |
(d) Remove the bolt and nut.
|
(e) Detach the clamps and remove the radiator reserve tank assembly. |
|
|
(f) Remove the bolt and disconnect the No. 2 ground wire. |
|
(g) Remove the 2 bolts and nut and remove the engine mounting insulator sub-assembly RH.
|
|
Bolt |
|
|
Nut |
79. REMOVE ENGINE MOUNTING SPACER
HINT:
Perform this procedure only when replacement of the engine mounting spacer is necessary.
|
(a) Remove the 2 bolts and engine mounting spacer from the vehicle body. |
|
80. REMOVE ECM
Click here
81. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY LH
HINT:
Perform this procedure only when replacement of the engine mounting insulator sub-assembly LH is necessary.
|
(a) Remove the bolt. |
|
(b) Detach the claw and disconnect the engine room main wire.
(c) Remove the 2 bolts, nut and the engine mounting insulator sub-assembly LH.
|
|
Bolt |
|
|
Nut |
|
|