A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL; 2024 MY RAV4 [10/2023

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM100000002FRH4
Model Year Start: 2024	Model: RAV4	Prod Date Range: [10/2023 - ]
Title: A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL; 2024 MY RAV4 [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 unit 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
1: When performing learning using the Techstream. Click here 2: w/o Power Back Door System
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)*1
		Pre-collision system
	Reset back door close position	Power back door system
	Back door lock initialization*2	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 Replacement of throttle body with motor assembly Replacement of cam timing control motor with EDU assembly Removal and installation of a cam timing control motor with EDU assembly Replacement of camshaft timing gear assembly Removal and installation of a camshaft timing gear assembly Replacement of cylinder head sub-assembly Replacement of camshaft (for intake or exhaust camshaft) Replacement of camshaft timing exhaust gear assembly Replacement of port fuel injector assembly Replacement of direct fuel injector assembly Replacement of fuel pump assembly (for high pressure side) Replacement of engine coolant temperature sensor Replacement of spark plug Replacement of ignition coil assembly Replacement of EGR valve assembly Replacement of knock control sensor Replacement of air fuel ratio sensor (sensor 2)	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

PROCEDURE

1. REMOVE DRIVE SHAFT BEARING BRACKET

(a) Remove the 3 bolts and drive shaft bearing bracket.

*A	for 2WD
*B	for 4WD/AWD

2. REMOVE V-RIBBED BELT

Click here

3. REMOVE GENERATOR ASSEMBLY

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

4. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY

(a) for Type A:

(1) Remove the 2 bolts and 2 nuts.

	Bolt
	Nut

(2) Using an E8 "TORX" socket wrench, remove the 2 stud bolts and compressor assembly with pulley.

(b) for Type B:

(1) Remove the 4 bolts and compressor assembly with pulley.

5. REMOVE NO. 2 ENGINE COVER

(a) Remove the 2 bolts and No. 2 engine cover from the No. 2 timing chain cover assembly.

6. REMOVE 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) Remove the 2 bolts and V-ribbed belt tensioner assembly from the No. 2 timing chain cover assembly.

7. REMOVE NO. 2 TIMING CHAIN COVER INSULATOR

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

8. REMOVE TIMING GEAR COVER INSULATOR

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

9. REMOVE NO. 3 TIMING CHAIN COVER

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

10. REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

(a) Slide the clip and disconnect the No. 2 water by-pass pipe sub-assembly from the outlet water by-pass sub-assembly.

(b) Remove the bolt and No. 2 water by-pass pipe sub-assembly.

11. REMOVE FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY)

(a) Remove the bolt to disconnect the flow shutting valve (water by-pass hose assembly).

(b) Remove the 2 bolts and the water hose clamp bracket.

(c) Slide the clip and disconnect the flow shutting valve (water by-pass hose assembly) from the water by-pass outlet sub-assembly.

HINT:

Use a container to catch any engine coolant which flows out of the flow shutting valve (water by-pass hose assembly) and water by-pass outlet sub-assembly.

12. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

(a) for Type A:

(1) Remove the 3 bolts and the No. 1 exhaust manifold heat insulator from the exhaust manifold.

(b) for Type B:

(1) Remove the 5 bolts and the No. 1 exhaust manifold heat insulator from the exhaust manifold.

13. REMOVE MANIFOLD STAY

Click here

14. REMOVE EXHAUST MANIFOLD

(a) Using a 12 mm deep socket wrench, remove the 7 nuts and separate the exhaust manifold from the cylinder head sub-assembly.

(b) Remove the exhaust manifold to head gasket from the cylinder head sub-assembly.

15. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

Click here

16. REMOVE EGR COOLER ASSEMBLY

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

(1) Remove the 2 bolts, 3 nuts, EGR cooler assembly, EGR cooler gasket and EGR valve gasket.

	Bolt
	Nut

(d) Type B:

(1) Remove the 3 bolts, 2 nuts, EGR cooler assembly, EGR cooler gasket and EGR valve gasket.

	Bolt
	Nut

17. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

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

18. REMOVE NO. 4 WATER BY-PASS HOSE

(a) Slide the clip and remove the No. 4 water by-pass hose from the EGR valve assembly.

19. REMOVE EGR VALVE ASSEMBLY

(a) Slide the clip and disconnect the No. 8 water by-pass hose from the EGR valve assembly.

(b) Using an 8 mm socket wrench, remove the 2 bolts.

*a	Pin
*b	Hole

20. REMOVE NO. 3 WATER BY-PASS PIPE

(a) Using an 8 mm socket wrench, remove the bolt and No. 3 water by-pass pipe from the intake manifold.

(b) Slide the clip and disconnect the No. 3 water by-pass pipe from the water outlet.

21. REMOVE NO. 2 WATER BY-PASS PIPE

(a) Remove the bolt (A).

(b) Using an 8 mm socket wrench, remove the 2 bolts (B) and No. 2 water by-pass pipe.

22. REMOVE INTAKE MANIFOLD

Click here

23. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

Click here

24. DISCONNECT FUEL TUBE SUB-ASSEMBLY

Click here

25. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 1 fuel pipe sub-assembly.

	Union Nut
	Bolt

(b) Remove the bolt and No. 1 fuel pipe sub-assembly.

26. REMOVE FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)

Click here

27. REMOVE NO. 7 WATER BY-PASS HOSE

(a) Slide the 2 clips and remove the No. 7 water by-pass hose.

28. REMOVE SENSOR WIRE

(a) Disconnect the 4 connectors.

(b) Detach the 3 clamps.

29. REMOVE NO. 6 ENGINE WIRE

(a) Disconnect the 4 connectors.

(b) Detach the 2 clamps.

30. REMOVE WIRE HARNESS CLAMP BRACKET

(a) Using an 8 mm socket wrench, remove the 2 bolts and wire harness clamp bracket from the No. 1 ventilation case.

31. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

Click here

32. REMOVE NO. 1 DELIVERY PIPE SPACER

Click here

33. REMOVE INJECTOR VIBRATION INSULATOR

Click here

34. REMOVE NO. 5 ENGINE WIRE

Click here

35. REMOVE PORT FUEL INJECTOR ASSEMBLY

Click here

36. REMOVE FUEL DELIVERY PIPE

Click here

37. REMOVE DIRECT FUEL INJECTOR ASSEMBLY

Click here

38. REMOVE FUEL INJECTOR SEAL

Click here

39. REMOVE IGNITION COIL ASSEMBLY

Click here

40. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

(a) Remove the engine oil level dipstick.

(b) Using an 8 mm socket wrench, remove the bolt and engine oil level dipstick guide from the cylinder head sub-assembly.

41. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

(a) Remove the bolt and No. 3 exhaust manifold heat insulator from the cylinder block sub-assembly.

42. REMOVE PURGE VALVE (PURGE VSV)

Click here

43. REMOVE NO. 2 VACUUM SWITCHING VALVE BRACKET

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

REMOVAL

CAUTION / NOTICE / HINT

Necessary Procedure After Parts Removed/Installed/Replaced

for UB80E:

for UB80F:

for UB80E:

for UB80F:

PROCEDURE