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 (5 Of 6) >> Engine Unit >> Installation [12/2021 - ] >> Procedure

Installation [12/2021 - ]: Procedure

  1. INSTALL NO. 2 VACUUM SWITCHING VALVE BRACKET 
    1. Using an 8 mm socket wrench, install the No. 2 vacuum switching valve bracket to the cylinder head sub-assembly with the 2 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  2. INSTALL PURGE VALVE (PURGE VSV) 

    Refer to PROCEDURE - Step 1

  3. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Install the No. 3 exhaust manifold heat insulator to the cylinder block sub-assembly with the bolt.

      Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) 

  4. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. Apply a light coat of engine oil to a new O-ring.
    2. Install the O-ring to the engine oil level dipstick guide.
    3. Using an 8 mm socket wrench, install the engine oil level dipstick guide to the cylinder head sub-assembly with the bolt.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    4. Install the engine oil level dipstick.
  5. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  6. INSTALL FUEL INJECTOR SEAL 

    Refer to PROCEDURE - Step 1

  7. INSTALL DIRECT FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  8. INSTALL FUEL DELIVERY PIPE 

    Refer to PROCEDURE - Step 3

  9. INSTALL PORT FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  10. INSTALL NO. 5 ENGINE WIRE 

    Refer to PROCEDURE - Step 2

  11. INSTALL INJECTOR VIBRATION INSULATOR 

    Refer to PROCEDURE - Step 3

  12. INSTALL NO. 1 DELIVERY PIPE SPACER 

    Refer to PROCEDURE - Step 4

  13. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  14. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Using an 8 mm socket wrench, install the wire harness clamp bracket to the No. 1 ventilation case with the 2 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  15. INSTALL NO. 6 ENGINE WIRE 
    1. Install the No. 6 engine wire to the wire harness clamp bracket with the 2 nuts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    2. Attach the 2 clamps.
    3. Connect the 4 connectors.
  16. INSTALL SENSOR WIRE 
    1. Using an 8 mm socket wrench, install the sensor wire to the water inlet with thermostat sub-assembly with the bolt.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    2. Attach the 3 clamps.
    3. Connect the 4 connectors.
  17. INSTALL NO. 7 WATER BY-PASS HOSE 
    1. Install the No. 7 water by-pass hose and slide the 2 clips to secure it.
  18. TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) 

    Refer to PROCEDURE - Step 1

  19. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  20. INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) 

    Refer to PROCEDURE - Step 3

  21. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 
    1. Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe side of the No. 1 fuel pipe sub-assembly.

      Specified tightening torque 

      Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf) 

      NOTE:

      Do not adjust the torque in the loosening direction.

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Refer to PRECAUTION [11/2018 - ]

      • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)
      GTY1000704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 17 mm Union Nut Wrench
      *b Torque Wrench Fulcrum Length
      Union Nut
      Bolt
    2. Using a 17 mm union nut wrench, tighten the union nut on the fuel pump assembly side of the No. 1 fuel pipe sub-assembly.

      Specified tightening torque 

      Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf) 

      NOTE:

      Do not adjust the torque in the loosening direction.

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Refer to PRECAUTION [11/2018 - ]

      • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)
    3. Connect the No. 1 fuel pipe sub-assembly to the cylinder head sub-assembly with the bolt.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  22. CONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  23. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET 

    Refer to PROCEDURE - Step 3

  24. INSTALL INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 4

  25. INSTALL NO. 2 WATER BY-PASS PIPE 
    1. Install the bolt (A).

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

      GTY1001610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an 8 mm socket wrench, install the No. 2 water by-pass pipe with the 2 bolts (B) in the order shown in the illustration.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  26. INSTALL NO. 3 WATER BY-PASS PIPE 
    1. Connect the No. 3 water by-pass pipe to the water outlet and slide the clip to secure it.
    2. Using an 8 mm socket wrench, install the No. 3 water by-pass pipe to the intake manifold with the bolt.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  27. SET EGR VALVE ASSEMBLY 
    1. Set the EGR valve assembly to the camshaft housing.

      HINT: 

      At this time, do not install the parts with bolts.

  28. INSTALL NO. 4 WATER BY-PASS HOSE 
    1. Connect the No. 4 water by-pass hose to the EGR valve assembly and slide the clip to secure it.
  29. INSTALL EGR COOLER ASSEMBLY 
    1. Install a new EGR cooler gasket to the EGR cooler assembly.
      GTY1001304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Claw
      NOTE:

      Make sure that the claws of the EGR cooler gasket are toward the EGR cooler assembly side.

    2. Install a new EGR valve gasket to the EGR cooler assembly.
      NOTE:

      Make sure that the claws of the EGR valve gasket are toward the EGR cooler assembly side.

    3. Type A:
      1. Temporarily install the EGR cooler assembly to the cylinder head sub-assembly and EGR valve assembly with the 2 bolts and 3 nuts.
        Fig 1: EGR Cooler Assembly Tightening Sequence
        GTY1000410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Bolt
        Nut
      2. Tighten the 2 bolts and 3 nuts in the order shown in the illustration.

        Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) 

    4. Type B:
      1. Temporarily install the EGR cooler assembly to the cylinder head sub-assembly and EGR valve assembly with the 3 bolts and 2 nuts.
        GTY1000993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Bolt
        Nut
      2. Tighten the 3 bolts and 2 nuts in the order shown in the illustration.

        Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) 

    5. Connect the No. 3 water by-pass hose to the EGR cooler assembly.
    6. Connect the No. 4 water by-pass hose to the EGR cooler assembly.
  30. INSTALL EGR VALVE ASSEMBLY 
    1. Using an 8 mm socket wrench, install the EGR valve assembly with the 2 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    2. Connect the No. 8 water by-pass hose to the EGR valve assembly and slide the clip to secure it.
  31. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY 
    1. Using an 8 mm socket wrench, install the No. 1 EGR pipe sub-assembly, a new EGR inlet gasket and a new EGR valve adapter gasket with the 4 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  32. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  33. INSTALL EXHAUST MANIFOLD 

    Refer to PROCEDURE - Step 2

  34. INSTALL MANIFOLD STAY 

    Refer to PROCEDURE - Step 3

  35. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    1. for Type A:
      1. Install the No. 1 exhaust manifold heat insulator to the exhaust manifold with the 3 bolts.

        Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

        GTY1000054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for Type B:
      1. Install the No. 1 exhaust manifold heat insulator to the exhaust manifold with the 5 bolts.

        Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

        GTY757874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY) 
    1. Connect the flow shutting valve (water by-pass hose assembly) to the water by-pass outlet sub-assembly and slide the clip to secure it.
      NOTE:
      • Make sure to slide the flow shutting valve (water by-pass hose assembly) until it contacts the hose stopper of the water by-pass outlet sub-assembly.
      • Make sure that the claws of the clip are within the location shown in the illustration.
      GTY872052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      *b 90°
      *c Upper Side
      *d RH Side
      *e 2 to 7 mm (0.0787 to 0.276 in.)
    2. Install the water hose clamp bracket with the 2 bolts.

      Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

    3. Connect the flow shutting valve (water by-pass hose assembly) with the bolt.

      Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 

  37. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY 
    1. Connect the No. 2 water by-pass pipe sub-assembly with the bolt.

      Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 

    2. Connect the No. 2 water by-pass pipe sub-assembly to the outlet water by-pass sub-assembly and slide the clip to secure it.
  38. INSTALL NO. 3 TIMING CHAIN COVER 
    1. Using an 8 mm socket wrench, install the No. 3 timing chain cover and plate washer to the No. 2 timing chain cover assembly with the bolt.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  39. INSTALL TIMING GEAR COVER INSULATOR 
    1. Using an 8 mm socket wrench, install the timing gear cover insulator and plate washer to the No. 2 timing chain cover assembly with the bolt.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  40. INSTALL NO. 2 TIMING CHAIN COVER INSULATOR 
    1. Install the No. 2 timing chain cover insulator to the V-ribbed belt tensioner assembly.
  41. INSTALL 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. Install the V-ribbed belt tensioner assembly to the No. 2 timing chain cover assembly with the 2 bolts.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

  42. INSTALL NO. 2 ENGINE COVER 
    1. Install the No. 2 engine cover to the No. 2 timing chain cover assembly with the 2 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  43. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY 
    1. for Type A:
      1. Using an E8 "TORX" socket wrench, temporarily install the compressor assembly with pulley with the 2 stud bolts.

        Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

      2. Install the compressor assembly with pulley with the 2 bolts and 2 nuts.
        GTY764544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Bolt
        Nut

        Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf) 

        HINT: 

        Tighten the bolts and nuts in the order shown in the illustration.

    2. for Type B:
      1. Install the compressor assembly with pulley with the 4 bolts.
        GTY765599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf) 

        HINT: 

        Tighten the bolts in the order shown in the illustration.

  44. INSTALL GENERATOR ASSEMBLY 
  45. INSTALL V-RIBBED BELT 

    Refer to PROCEDURE - Step 1

  46. INSTALL DRIVE SHAFT BEARING BRACKET 
    1. Install the drive shaft bearing bracket with the 3 bolts.

      Torque: 63.7 N*m (650 kgf*cm, 47 ft.*lbf) 

scientia non olet · About LEMON Manuals