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Home >> Toyota >> 2020 >> RAV4 XLE, AWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 142 (Engine Mechanical System (A25A-FXS) - Service Information (2 Of 6)) >> Engine Assembly >> Removal [11/2018 - 02/2019] >> Procedure

Removal [11/2018 - 02/2019]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. PRECAUTION 
    NOTE:

    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.

    Refer to PRECAUTION [11/2018 - ]

  2. REMOVE DECK BOARD ASSEMBLY 

    Refer to PROCEDURE - Step 2

  3. REMOVE REAR NO. 2 FLOOR BOARD 

    Refer to PROCEDURE - Step 3

  4. REMOVE BATTERY HOLE COVER 

    Refer to PROCEDURE - Step 4

  5. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL 

    Refer to PROCEDURE - Step 5

  6. REMOVE BATTERY SERVICE HOLE COVER 

    Refer to PROCEDURE - Step 1

  7. REMOVE SERVICE PLUG GRIP 

    Refer to PROCEDURE - Step 8

  8. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 

    Refer to PROCEDURE - Step 1

  9. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [11/2018 - 02/2019]

  10. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  11. SECURE STEERING WHEEL 

    Refer to PROCEDURE - Step 3

  12. REMOVE FRONT WHEELS 

    Refer to REMOVAL [11/2018 - ]

  13. REMOVE FRONT FENDER FRONT SPLASH SHIELD LH 
    1. Remove the 3 screws.
      GTY847985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the clip and remove the front fender front splash shield LH.
  14. REMOVE FRONT FENDER FRONT SPLASH SHIELD RH 
    1. Remove the 3 screws.
      GTY847986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the clip and remove the front fender front splash shield RH.
  15. REMOVE NO. 1 ENGINE UNDER COVER 
    1. Remove the 2 bolts and 10 screws.
    2. Detach the guide and remove the No. 1 engine under cover.
      GTY941760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt Screw
  16. REMOVE NO. 2 ENGINE UNDER COVER ASSEMBLY 
    1. Remove the 2 bolts, 2 screws, 6 clips and No. 2 engine under cover assembly.
      GTY924569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
      Clip
  17. 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
  18. 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
  19. REMOVE FRONT BUMPER ASSEMBLY 

    Refer to REMOVAL [11/2018 - 02/2019]

  20. REMOVE HEADLIGHT ASSEMBLY LH 

    Refer to REMOVAL [11/2018 - 02/2019]

  21. REMOVE FRONT LOWER BUMPER ABSORBER 
    1. Remove the clip.
      GTY847909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the claws and remove the front lower bumper absorber.
  22. REMOVE FRONT BUMPER NO. 2 REINFORCEMENT 

    Refer to PROCEDURE - Step 10

  23. DRAIN ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 1

  24. DRAIN ENGINE OIL 

    Refer to PROCEDURE - Step 2

  25. DRAIN HYBRID TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 6

  26. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. GTY847982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.

  27. REMOVE INLET AIR CLEANER ASSEMBLY 

    Refer to PROCEDURE - Step 3

  28. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 4

  29. REMOVE INVERTER WITH CONVERTER ASSEMBLY 

    Refer to REMOVAL [11/2018 - 02/2019]

  30. REMOVE INVERTER RESERVE TANK ASSEMBLY 
    1. Remove the 2 bolts.
      GTY851588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 2 Inverter Cooling Hose
      *2 No. 5 Inverter Cooling Hose
      *a Pin
      *b Grommet
      Bolt
      Clip
    2. Detach the pin and remove the inverter reserve tank assembly.
    3. 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 
    1. Slide the 2 clips and remove the No. 5 water by-pass hose from the No. 3 water by-pass pipe and radiator assembly.
      GTY928349Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE 
    1. Detach the clamp.
      GTY847997Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the No. 1 fuel vapor feed hose from the purge VSV.
  33. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Remove the No. 1 fuel pipe clamp from the fuel tube connector.

      Refer to PRECAUTION [11/2018 - 02/2019]

      GTY847999Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel tube sub-assembly.
      1. Disconnect the fuel tube sub-assembly from the fuel pipe.

        Refer to PRECAUTION [11/2018 - 02/2019]

        GTY928350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. DISCONNECT OUTLET HEATER WATER HOSE 
    1. 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.
      GTY897250Courtesy 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.
  35. DISCONNECT INLET HEATER WATER HOSE 
    1. 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).
      GTY913269Courtesy 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.
  36. DISCONNECT NO. 1 RADIATOR HOSE 
    1. Detach the clamp.
      GTY847990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clip and disconnect the No. 1 radiator hose from the water outlet.
  37. DISCONNECT NO. 2 RADIATOR HOSE 
    1. Slide the clip and disconnect the No. 2 radiator hose from the water inlet.
      GTY847991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE 

    Refer to PROCEDURE - Step 13

  39. DISCONNECT SUCTION HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 12

  40. DISCONNECT NO. 5 INVERTER COOLING HOSE 
    1. Slide the clip and disconnect the No. 5 inverter cooling hose from the motor cooling cooler.
      GTY847992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not pull the No. 5 inverter cooling hose with excessive force to deform the motor cooling cooler pipe.
      • If the motor cooling cooler pipe is deformed replace it because using a deformed pipe can cause coolant leakage.
  41. 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 claws and remove the No. 2 relay block cover.
      GTY928348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut from the engine room relay block and junction block assembly.
      GTY868709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Nut
      Connector
    3. Disconnect the 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.
      GTY847901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 2 bolts and disconnect the ground wires.
  42. REMOVE ENGINE UNDER COVER HEAT INSULATOR 
    1. Remove the 2 clips and engine under cover heat insulator.
      GTY847979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE FRONT FLOOR COVER LH 
    1. Remove the 2 bolts, 4 screws and clip.
      GTY874744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
      Clip
    2. Detach the clips and remove the front floor cover LH.
  44. REMOVE FRONT FLOOR COVER RH 
    1. Remove the 2 bolts, 3 screws and clip.
      GTY934985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
      Clip
    2. Detach the clips and remove the front floor cover RH.
  45. REMOVE FRONT EXHAUST PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 3

  46. REMOVE FRONT AXLE SHAFT NUT LH 

    Refer to PROCEDURE - Step 3

  47. REMOVE FRONT AXLE SHAFT NUT RH 

    HINT: 

    Use the same procedure described for the LH side.

  48. DISCONNECT FRONT SPEED SENSOR LH 

    Refer to PROCEDURE - Step 4

  49. DISCONNECT FRONT SPEED SENSOR RH 

    HINT: 

    Use the same procedure described for the LH side.

  50. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH 

    Refer to PROCEDURE - Step 1

  51. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH 

    HINT: 

    Use the same procedure described for the LH side.

  52. DISCONNECT TIE ROD ASSEMBLY LH 

    Refer to PROCEDURE - Step 6

  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 

    Refer to PROCEDURE - Step 8

  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 

    Refer to PROCEDURE - Step 16

  57. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH 

    Refer to PROCEDURE - Step 17

  58. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 5

  59. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine assembly with transaxle on an engine lifter.
      GTY912341Courtesy 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.
      GTY890426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    3. Remove the 3 bolts and the engine mounting stay LH from the engine mounting insulator sub-assembly LH.
      GTY847912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 4 bolts and separate the engine mounting insulator sub-assembly LH from the hybrid vehicle transaxle assembly.
      GTY847913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. GTY939261Courtesy 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.

    6. 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.
    7. 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.
  60. REMOVE FUEL DELIVERY GUARD 
    1. Remove the bolt and fuel delivery guard from the engine mounting bracket RH.
      GTY761402Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. INSTALL ENGINE HANGERS 
    1. Install the No. 1 engine hanger and No. 2 engine hanger with the 4 bolts as shown in the illustration.
      GTY769283Courtesy 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.
  62. REMOVE FLYWHEEL HOUSING UNDER COVER 
    1. Remove the flywheel housing under cover from the cylinder block sub-assembly.
      GTY753666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. REMOVE FRONT FRAME ASSEMBLY 

    Refer to PROCEDURE - Step 6

  64. REMOVE FRONT ENGINE MOUNTING INSULATOR 

    HINT: 

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

    Refer to PROCEDURE - Step 12

  65. REMOVE WIRING HARNESS CLAMP BRACKET 
    1. Detach the clamps and disconnect the engine wire.
      GTY847915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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.

    1. GTY847908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Detach the clamp and disconnect the engine wire.

    2. Remove the bolt and rear engine mounting insulator from the rear engine mounting bracket.
  67. REMOVE ENGINE WIRE 
    1. Remove the engine wire from the engine assembly.
  68. REMOVE HV AIR CONDITIONING WIRE 
    1. Detach the clamps.
      GTY768590Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, slide the green-colored lock of the connector as shown in the illustration to release it and disconnect the connector.
      GTY743434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Green-colored Lock
      Slide
      WARNING:

      Make sure to wear insulated gloves.

      NOTE:

      Insulate the disconnected terminals and connector with insulating tape.

    3. Remove the bolt.
      GTY747656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Detach the guide to remove the HV air conditioning wire from the hybrid vehicle transaxle assembly.
  69. REMOVE STARTER HOLE INSULATOR 

    Refer to PROCEDURE - Step 9

  70. REMOVE FLYWHEEL HOUSING SIDE COVER 

    Refer to PROCEDURE - Step 10

  71. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY 

    Refer to PROCEDURE - Step 17

  72. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY 

    See step  2

  73. REMOVE FLYWHEEL SUB-ASSEMBLY 

    See step  3

  74. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE 

    See step  4

  75. INSTALL ENGINE ASSEMBLY TO ENGINE STAND 
    1. Install the engine assembly to an engine stand.
  76. 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.
  77. REMOVE NO. 1 INVERTER RESERVE TANK BRACKET 
    1. Remove the bolt and No. 1 inverter reserve tank bracket.
      GTY847924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.

    1. Disconnect the connector.
      GTY853926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Suction Pipe Sub-assembly
      *2 Air Conditioning Tube And Accessory Assembly
    2. Detach the clamps and disconnect the suction pipe sub-assembly and air conditioning tube and accessory assembly.
    3. Disconnect the No. 6 water by-pass hose and detach the clamp.
      GTY868420Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      No. 6 Water By-pass Hose
      Bolt
      Nut
    4. Remove the bolt and nut.
    5. Detach the clamps and remove the radiator reserve tank assembly.
      GTY928333Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the bolt and disconnect the No. 2 ground wire.
      GTY847927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 2 bolts and nut and remove the engine mounting insulator sub-assembly RH.
      GTY874382Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
  79. REMOVE ENGINE MOUNTING SPACER 

    HINT: 

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

    1. GTY847929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  80. REMOVE ECM 

    Refer to PROCEDURE - Step 6

  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.

    1. Remove the bolt.
      GTY928331Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the claw and disconnect the engine room main wire.
    3. Remove the 2 bolts, nut and the engine mounting insulator sub-assembly LH.
      GTY909047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
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