LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2019 >> RAV4 XLE, FWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical System (A25A-FKS) - Service Information (4 Of 6) >> Engine Unit >> Removal [11/2018 - 10/2019] >> Procedure

Removal [11/2018 - 10/2019]: Procedure

  1. REMOVE DRIVE SHAFT BEARING BRACKET 
    1. Remove the 3 bolts and drive shaft bearing bracket.
      GTY918733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for 2WD
      *B for 4WD/AWD
  2. REMOVE V-RIBBED BELT 

    Refer to PROCEDURE - Step 2

  3. REMOVE GENERATOR ASSEMBLY 
  4. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY 
    1. for Type A:
      1. Remove the 2 bolts and 2 nuts.
        GTY764543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Bolt
        Nut
      2. Using an E8 "TORX" socket wrench, remove the 2 stud bolts and compressor assembly with pulley.
        GTY766845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for Type B:
      1. Remove the 4 bolts and compressor assembly with pulley.
        GTY751973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE NO. 2 ENGINE COVER 
    1. Remove the 2 bolts and No. 2 engine cover from the No. 2 timing chain cover assembly.
      GTY771428Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY 
    NOTE:
    • 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.
    GTY743260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 2 bolts and V-ribbed belt tensioner assembly from the No. 2 timing chain cover assembly.
      GTY756774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE NO. 2 TIMING CHAIN COVER INSULATOR 
    1. Remove the No. 2 timing chain cover insulator from the V-ribbed belt tensioner assembly.
      GTY772109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE TIMING GEAR COVER INSULATOR 
    1. Using an 8 mm socket wrench, remove the bolt, plate washer and timing gear cover insulator from the No. 2 timing chain cover assembly.
      GTY760321Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE NO. 3 TIMING CHAIN COVER 
    1. 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.
      GTY760320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY 
    1. Slide the clip and disconnect the No. 2 water by-pass pipe sub-assembly from the outlet water by-pass sub-assembly.
      GTY859051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and No. 2 water by-pass pipe sub-assembly.
  11. REMOVE FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY) 
    1. Remove the bolt to disconnect the flow shutting valve (water by-pass hose assembly).
      GTY761485Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and the water hose clamp bracket.
      GTY761486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Slide the clip and disconnect the flow shutting valve (water by-pass hose assembly) from the water by-pass outlet sub-assembly.
      GTY761484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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 
    1. Remove the 5 bolts and No. 1 exhaust manifold heat insulator from the exhaust manifold.
      GTY757874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE MANIFOLD STAY 

    Refer to PROCEDURE - Step 7 [11/2018 - 02/2019] , or refer to PROCEDURE - Step 7 [02/2019 - 08/2020]

  14. REMOVE EXHAUST MANIFOLD 
    1. Using a 12 mm deep socket wrench, remove the 7 nuts and separate the exhaust manifold from the cylinder head sub-assembly.
      GTY757875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the exhaust manifold to head gasket from the cylinder head sub-assembly.
      GTY772347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 5

  16. REMOVE EGR COOLER ASSEMBLY 
    1. Slide the clip and disconnect the water hose from the EGR cooler assembly.
      GTY849084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 3 Water By-pass Hose
      *2 Water Hose
    2. Slide the clip and disconnect the No. 3 water by-pass hose from the EGR cooler assembly.
    3. Remove the 5 bolts, EGR cooler assembly, EGR cooler gasket and EGR valve gasket.
      GTY760317Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE NO. 1 EGR COOLER BRACKET 
    1. Remove the 2 bolts and No. 1 EGR cooler bracket from the EGR valve bracket and water outlet.
      GTY772888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY 
    1. Using an 8 mm socket wrench, remove the 4 bolts, No. 1 EGR pipe sub-assembly, EGR inlet gasket and EGR valve adapter gasket.
      GTY760319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE NO. 4 WATER BY-PASS HOSE 
    1. GTY871549Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  20. REMOVE EGR VALVE ASSEMBLY 
    1. Disconnect the clamp.
      GTY760315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clip and disconnect the No. 8 water by-pass hose from the EGR valve assembly.
    3. Using an 8 mm socket wrench, remove the bolt and disconnect the fuel pipe sub-assembly from the EGR valve bracket.
      GTY760314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using an 8 mm socket wrench, remove the bolt.
    5. Remove the EGR valve assembly vertically.
      GTY769367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin
      *b Hole
    6. Using an 8 mm socket wrench, remove the bolt and EGR valve bracket.
      GTY760316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE NO. 3 WATER BY-PASS PIPE 
    1. Using an 8 mm socket wrench, remove the bolt and No. 3 water by-pass pipe from the intake manifold.
      GTY772887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clip and disconnect the No. 3 water by-pass pipe from the water outlet.
  22. REMOVE NO. 2 WATER BY-PASS PIPE 
    1. Remove the bolt (A).
      GTY741106Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an 8 mm socket wrench, remove the 2 bolts (B) and No. 2 water by-pass pipe.
  23. REMOVE INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 8 [11/2018 - 02/2019] , or refer to PROCEDURE - Step 8 [02/2019 - 08/2020]

  24. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET 

    Refer to PROCEDURE - Step 9 [11/2018 - 02/2019] , or refer to PROCEDURE - Step 9 [02/2019 - 08/2020]

  25. DISCONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  26. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY 
    1. Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 1 fuel pipe sub-assembly.
      GTY768505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) 

    Refer to PROCEDURE - Step 7

  28. REMOVE NO. 7 WATER BY-PASS HOSE 
    1. Slide the 2 clips and remove the No. 7 water by-pass hose.
      GTY760313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE SENSOR WIRE 
    1. Disconnect the 4 connectors.
      GTY756554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the 3 clamps.
    3. Using an 8 mm socket wrench, remove the bolt and sensor wire from the water inlet with thermostat sub-assembly.
  30. REMOVE NO. 6 ENGINE WIRE 
    1. Disconnect the 4 connectors.
      GTY756553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the 2 clamps.
    3. Remove the 2 nuts and No. 6 engine wire from the wire harness clamp bracket.
  31. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. Using an 8 mm socket wrench, remove the 2 bolts and wire harness clamp bracket from the No. 1 ventilation case.
      GTY772063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 7

  33. REMOVE NO. 1 DELIVERY PIPE SPACER 

    Refer to PROCEDURE - Step 8

  34. REMOVE INJECTOR VIBRATION INSULATOR 

    Refer to PROCEDURE - Step 9

  35. REMOVE NO. 5 ENGINE WIRE 

    Refer to PROCEDURE - Step 10

  36. REMOVE PORT FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 11

  37. REMOVE FUEL DELIVERY PIPE 

    Refer to PROCEDURE - Step 6

  38. REMOVE DIRECT FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 7

  39. REMOVE FUEL INJECTOR SEAL 

    Refer to PROCEDURE - Step 8

  40. REMOVE IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  41. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. Remove the engine oil level dipstick.
    2. Using an 8 mm socket wrench, remove the bolt and engine oil level dipstick guide from the cylinder head sub-assembly.
      GTY756776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the O-ring from the engine oil level dipstick guide.
      GTY756777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Remove the 2 bolts and No. 3 exhaust manifold heat insulator from the cylinder block sub-assembly.
      GTY760312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE PURGE VALVE (PURGE VSV) 
  44. REMOVE NO. 2 VACUUM SWITCHING VALVE BRACKET 
    1. Using an 8 mm socket wrench, remove the 2 bolts and No. 2 vacuum switching valve bracket from the cylinder head sub-assembly.
      GTY754235Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
scientia non olet · About LEMON Manuals