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Home >> Toyota >> 2020 >> RAV4 XLE, AWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical System (A25A-FKS) - Service Information (3 Of 6) >> Engine Assembly >> Removal [10/2022 - 10/2023] >> Procedure

Removal [10/2022 - 10/2023]: Procedure

  1. PRECAUTION 
    NOTE:

    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.

    Refer to PRECAUTION [11/2018 - ]

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 

    Refer to PROCEDURE - Step 1

  3. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [08/2020 - ]

  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    NOTE:

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

    Refer to INITIALIZATION [10/2022 - 10/2023]

  5. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  6. SECURE STEERING WHEEL 

    Refer to PROCEDURE - Step 3

  7. REMOVE FRONT WHEELS 

    Refer to PROCEDURE - Step 1

  8. REMOVE FRONT FENDER FRONT SPLASH SHIELD LH 
    1. GTY847985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      for Short Type:

      1. Remove the 3 screws.
      2. Detach the clip and remove the front fender front splash shield LH.
    2. GTY847919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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 
    1. GTY847986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      for Short Type:

      1. Remove the 3 screws.
      2. Detach the clip and remove the front fender front splash shield RH.
    2. GTY847920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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 
    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.
      GTY908860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Short Type Front Fender Front Splash Shield - -
      Bolt Screw
  11. REMOVE NO. 2 ENGINE UNDER COVER ASSEMBLY 
    1. Remove the 2 bolts, 2 screws, 6 clips and No. 2 engine under cover assembly.
      GTY914296Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
  12. REMOVE FRONT FENDER APRON SEAL LH 
    1. Remove the 2 bolts, clip and front fender apron seal LH.
      GTY915278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Clip
  13. REMOVE FRONT FENDER APRON SEAL RH 
    1. Remove the 2 bolts, clip and front fender apron seal RH.
      GTY927625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Clip
  14. REMOVE FRONT BUMPER ASSEMBLY 
  15. REMOVE FRONT LOWER BUMPER ABSORBER 
    1. Remove the 5 bolts.
      GTY905059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the 2 claws and remove the front lower bumper absorber.
  16. DRAIN ENGINE COOLANT 

    Refer to PROCEDURE - Step 1

  17. DRAIN ENGINE OIL 

    Refer to PROCEDURE - Step 2

  18. DRAIN AUTOMATIC TRANSAXLE FLUID 
  19. DRAIN TRANSFER OIL (for AWD) 
  20. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. 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.
      NOTE:

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

      GTY930792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE INLET AIR CLEANER ASSEMBLY 

    Refer to PROCEDURE - Step 3

  22. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 4

  23. REMOVE ECM 

    Refer to PROCEDURE - Step 5

  24. REMOVE BATTERY 

    Refer to PROCEDURE - Step 3

  25. REMOVE BATTERY CLAMP SUB-ASSEMBLY 
    1. Detach the 2 clamps from the battery clamp sub-assembly.
      GTY886437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the 2 clamps and disconnect the engine room main wire and No. 2 engine wire from the battery clamp sub-assembly.
      GTY843916Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 2 Engine Wire
      *2 Engine Room Main Wire
      *3 Positive (+) Battery Terminal
    3. Remove the nut and disconnect the engine room main wire and No. 2 engine wire from the positive (+) battery terminal.
    4. Detach the 2 claws and disconnect the engine room main wire from the No. 2 engine wire.
    5. Remove the 3 bolts and battery clamp sub-assembly.
      GTY885829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. DISCONNECT NO. 3 ENGINE WIRE 
    1. Detach the clamp from the bracket.
      GTY885824Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and disconnect the No. 3 engine wire from the automatic transaxle assembly.
  27. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. 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.
      GTY887893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Clip
      *b 45° to 60°
    2. Remove the clip and disconnect the transmission control cable assembly from the No. 1 transmission control cable bracket.
      GTY852853Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE 
    1. Slide the clip and disconnect the No. 1 fuel vapor feed hose from the Purge VSV.
      GTY885826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. DISCONNECT UNION TO CHECK VALVE HOSE 
    1. Slide the clip and disconnect the union to check valve hose from the vacuum pump assembly.
      GTY936658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. DISCONNECT NO. 1 VACUUM HOSE CONNECTOR 

    Refer to PROCEDURE - Step 1

  31. DISCONNECT INLET HEATER WATER HOSE 
    1. Pull out the retainer to detach the lock claws and pull off the inlet heater water hose.
      GTY935999Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer
      Pull out
      Pull off
    2. Check that there is no foreign matter on the sealing surfaces of the disconnected water lines. Clean them if necessary.
    3. 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 
    1. Pull out the retainer to detach the lock claws and pull off the outlet heater water hose.
      GTY938500Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer
      Pull out
      Pull off
    2. Check that there is no foreign matter on the sealing surfaces of the disconnected water lines. Clean them if necessary.
    3. 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 
    1. Remove the No. 1 fuel pipe clamp from the fuel tube connector.
      GTY885823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to PRECAUTION [08/2020 - ]

    2. Disconnect the fuel tube sub-assembly.
      1. Disconnect the fuel tube sub-assembly from the fuel pipe.
        GTY936659Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Refer to PRECAUTION [08/2020 - ]

  34. DISCONNECT NO. 1 RADIATOR HOSE 
    1. Remove the clamp to disconnect the No. 1 radiator hose from the No. 1 radiator bracket.
      GTY885838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clip and disconnect the No. 1 radiator hose from the water outlet.
  35. DISCONNECT NO. 2 RADIATOR HOSE 
    1. Detach the clamp and disconnect the No. 2 radiator hose from the fan with motor assembly.
      GTY936661Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clip and disconnect the No. 2 radiator hose from the radiator assembly.
  36. DISCONNECT SUCTION HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

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

    Refer to PROCEDURE - Step 7

  38. DISCONNECT WIRE HARNESS 

    HINT: 

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

    1. Detach the 3 claws and remove the No. 2 relay block cover.
      GTY885836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut from the engine room relay block and junction block assembly.
      GTY885837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the 5 connectors from the engine room relay block and junction block assembly.
    4. Using a screwdriver, detach the claw and disconnect the wire harness from the engine room relay block and junction block assembly.
    5. Detach the clamp.
      GTY885831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the bolt and disconnect the wire harness from the vehicle body.
  39. REMOVE NO. 5 WATER BY-PASS HOSE 
    1. Slide the 2 clips and remove the No. 5 water by-pass hose from the radiator assembly and No. 3 water by-pass pipe.
      GTY885832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE FRONT FLOOR COVER LH (w/ Cover) 

    Refer to PROCEDURE - Step 13

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

    Refer to PROCEDURE - Step 14

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

    Refer to PROCEDURE - Step 15

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

    Refer to PROCEDURE - Step 16

  44. REMOVE FRONT EXHAUST PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 2

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

    Refer to PROCEDURE - Step 2

  46. REMOVE PROPELLER SHAFT ASSEMBLY (for AWD) 

    Refer to PROCEDURE - Step 3

  47. REMOVE FRONT AXLE SHAFT NUT LH 

    Refer to PROCEDURE - Step 3

  48. REMOVE FRONT AXLE SHAFT NUT RH 

    HINT: 

    Use the same procedure described for the LH side.

  49. DISCONNECT FRONT SPEED SENSOR LH 

    Refer to PROCEDURE - Step 4

  50. DISCONNECT FRONT SPEED SENSOR RH 

    HINT: 

    Use the same procedure described for the LH side.

  51. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH 

    Refer to PROCEDURE - Step 1

  52. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH 

    HINT: 

    Use the same procedure described for the LH side.

  53. DISCONNECT TIE ROD ASSEMBLY LH 

    Refer to PROCEDURE - Step 6

  54. DISCONNECT TIE ROD ASSEMBLY RH 

    HINT: 

    Use the same procedure described for the LH side.

  55. DISCONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 8

  56. DISCONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH 

    HINT: 

    Use the same procedure described for the LH side.

  57. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH 
  58. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH 
  59. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH 
  60. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 5

  61. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine assembly with transaxle on an engine lifter.
      GTY900168Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Attachments - -
      NOTE:
      • 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.
    2. Remove the 3 bolts and nut and separate the engine mounting insulator sub-assembly RH from the engine mounting bracket RH.
      GTY885834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and nut and separate the engine mounting insulator LH from the engine mounting bracket sub-assembly LH.
      GTY899279Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    4. GTY921088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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

      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.

    5. 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.
    6. Operate the engine lifter and remove the engine assembly with transaxle from the vehicle.
      NOTE:
      • 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.
  62. REMOVE FUEL DELIVERY GUARD 
    1. Remove the bolt and fuel delivery guard from the engine mounting bracket RH.
      GTY885846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. INSTALL ENGINE HANGERS 
    1. Install the No. 1 engine hanger and No. 2 engine hanger with the 4 bolts as shown in the illustration.
      GTY844816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

      HINT: 

      No. 1 Engine Hanger 12281-25030
      No. 2 Engine Hanger 12282-25010
      Bolt 91552-F1040
    2. Using an engine sling device and engine lift, secure the engine assembly with transaxle.
      NOTE:
      • 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.
  64. REMOVE FLYWHEEL HOUSING UNDER COVER 
    1. Remove the flywheel housing under cover from the cylinder block sub-assembly.
      GTY885844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT 
  66. DISCONNECT VACUUM HOSE 
  67. REMOVE FLOW SHUTTING VALVE (NO. 1 WATER BY-PASS HOSE) 

    Refer to PROCEDURE - Step 11

  68. DISCONNECT WATER BY-PASS HOSE ASSEMBLY 
  69. REMOVE BREATHER PLUG HOSE 
  70. REMOVE STEERING GEAR HEAT INSULATOR 

    Refer to PROCEDURE - Step 9

  71. DISCONNECT WIRE HARNESS 
  72. REMOVE FRONT FRAME ASSEMBLY 
  73. REMOVE VACUUM SWITCHING VALVE (for Active Control Engine Mount System) 

    Refer to PROCEDURE - Step 4

  74. REMOVE FRONT ENGINE MOUNTING INSULATOR 

    HINT: 

    Perform this procedure only when replacement of the front engine mounting insulator is necessary.

  75. REMOVE FRONT ENGINE MOUNTING BRACKET 
  76. REMOVE REAR ENGINE MOUNTING INSULATOR (for 2WD) 

    HINT: 

    Perform this procedure only when replacement of the rear engine mounting insulator is necessary.

    Refer to PROCEDURE - Step 2

  77. REMOVE PROPELLER SHAFT HEAT INSULATOR (for AWD) 

    Refer to PROCEDURE - Step 18

  78. REMOVE REAR ENGINE MOUNTING INSULATOR (for AWD) 

    HINT: 

    Perform this procedure only when replacement of the rear engine mounting insulator is necessary.

    Refer to PROCEDURE - Step 2

  79. REMOVE REAR ENGINE MOUNTING BRACKET SUB-ASSEMBLY 
  80. REMOVE FLYWHEEL HOUSING SIDE COVER 
  81. REMOVE STARTER ASSEMBLY 
  82. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY 
  83. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  84. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE 

    Refer to PROCEDURE - Step 3

  85. REMOVE ENGINE WIRE 
    1. Remove the engine wire from the engine assembly.
  86. INSTALL ENGINE ASSEMBLY TO ENGINE STAND 
    1. Install the engine assembly to an engine stand.
  87. REMOVE ENGINE HANGERS 
    1. Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger from the cylinder head sub-assembly and engine mounting bracket RH.
  88. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH 

    HINT: 

    Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.

    1. Disconnect the connector.
      GTY868152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Suction Pipe Sub-assembly
      *2 Air Conditioning Tube And Accessory Assembly
    2. Detach the 2 clamps and disconnect the suction pipe sub-assembly and air conditioning tube and accessory assembly.
    3. Disconnect the No. 6 water by-pass hose.
      GTY885842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Detach the clamp.
    5. Remove the bolt, nut and the radiator reserve tank assembly.
      GTY936662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Detach the 2 clamps and disconnect the wire harness from the radiator reserve tank assembly.
    7. Remove the bolt and disconnect the No. 2 ground wire from the engine mounting insulator sub-assembly RH.
      GTY885852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the 2 bolts, nut and engine mounting insulator sub-assembly RH.
      GTY885853Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  89. REMOVE ENGINE MOUNTING SPACER 

    HINT: 

    Perform this procedure only when replacement of the engine mounting spacer is necessary.

    1. GTY885854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the 2 bolts and engine mounting spacer from the vehicle body.

  90. REMOVE ENGINE MOUNTING INSULATOR LH 

    HINT: 

    Perform this procedure only when replacement of the engine mounting insulator LH is necessary.

  91. REMOVE ENGINE MOUNTING BRACKET SUB-ASSEMBLY LH 
    1. Remove the 4 bolts and engine mounting bracket sub-assembly LH from the vehicle body.
      GTY885855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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