LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2020 >> RAV4 XLE, AWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 159 (Engine Mechanical System (A25A-FXS) - Service Information (4 Of 6)) >> Engine Unit >> Removal [10/2023 - ] >> Procedure

Removal [10/2023 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE DRIVE SHAFT BEARING BRACKET 
    1. Remove the 3 bolts and drive shaft bearing bracket.
      GTY773125Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY 
    1. Remove the bolt and 2 nuts.
      GTY744326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    2. Using an E8 "TORX" socket wrench, remove the 2 stud bolts and compressor assembly with pulley.
      GTY751975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. 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.
      GTY761392Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and the No. 2 water by-pass pipe sub-assembly.
  4. REMOVE FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY) 
    1. Remove the bolt.
      GTY761393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clip and disconnect the flow shutting valve (water by-pass hose assembly) from the water by-pass outlet sub-assembly.
      GTY761391Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and water hose clamp bracket.
      GTY743374Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    1. for Type A:
      1. Remove the 3 bolts and the No. 1 exhaust manifold heat insulator from the exhaust manifold.
        GTY1000054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for Type B:
      1. Remove the 5 bolts and the No. 1 exhaust manifold heat insulator from the exhaust manifold.
        GTY757874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE MANIFOLD STAY 

    Refer to PROCEDURE - Step 8

  7. 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.
      GTY1001044Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the exhaust manifold to head gasket from the cylinder head sub-assembly.
      GTY761390Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 5

  9. REMOVE EGR COOLER ASSEMBLY 
    1. Slide the clip and disconnect the No. 4 water by-pass hose from the EGR cooler assembly.
      GTY1000250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 3 Water By-pass Hose
      *2 No. 4 Water By-pass Hose
    2. Slide the clip and disconnect the No. 3 water by-pass hose from the EGR cooler assembly.
    3. Type A:
      1. Remove the 2 bolts, 3 nuts, EGR cooler assembly, EGR cooler gasket and EGR valve gasket.
        GTY1000212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Bolt
        Nut
    4. Type B:
      1. Remove the 3 bolts, 2 nuts, EGR cooler assembly, EGR cooler gasket and EGR valve gasket.
        GTY1000854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Bolt
        Nut
  10. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  11. REMOVE NO. 4 WATER BY-PASS HOSE 
    1. Slide the clip and remove the No. 4 water by-pass hose from the EGR valve assembly.
      GTY1002488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE EGR VALVE ASSEMBLY 
    1. Slide the clip and disconnect the No. 8 water by-pass hose from the EGR valve assembly.
      GTY1000927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an 8 mm socket wrench, remove the bolt.
      GTY1000926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the EGR valve assembly vertically.
      GTY1000511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin
      *b Hole
  13. 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.
      GTY761383Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clip and disconnect the No. 3 water by-pass pipe from the water outlet.
  14. REMOVE NO. 2 WATER BY-PASS PIPE 
    1. Remove the bolt (A).
      GTY1002389Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an 8 mm socket wrench, remove the 2 bolts (B) and No. 2 water by-pass pipe.
  15. REMOVE INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 9

  16. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET 

    Refer to PROCEDURE - Step 10

  17. DISCONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 8

  18. 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.
      GTY1001295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Union Nut
      Bolt
    2. Remove the bolt and No. 1 fuel pipe sub-assembly.
  19. REMOVE FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) 

    Refer to PROCEDURE - Step 11

  20. REMOVE NO. 7 WATER BY-PASS HOSE 
    1. Slide the 2 clips and remove the No. 7 water by-pass hose.
      GTY773122Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE SENSOR WIRE 
    1. Disconnect the 4 connectors.
      GTY761379Courtesy 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.
  22. REMOVE NO. 6 ENGINE WIRE 
    1. Disconnect the 4 connectors.
      GTY761380Courtesy 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.
  23. 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.
      GTY761514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 12

  25. REMOVE NO. 1 DELIVERY PIPE SPACER 

    Refer to PROCEDURE - Step 13

  26. REMOVE INJECTOR VIBRATION INSULATOR 

    Refer to PROCEDURE - Step 14

  27. REMOVE NO. 5 ENGINE WIRE 

    Refer to PROCEDURE - Step 15

  28. REMOVE PORT FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 16

  29. REMOVE FUEL DELIVERY PIPE 

    Refer to PROCEDURE - Step 9

  30. REMOVE DIRECT FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 10

  31. REMOVE FUEL INJECTOR SEAL 

    Refer to PROCEDURE - Step 11

  32. REMOVE IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  33. 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
  34. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Remove the bolt and No. 3 exhaust manifold heat insulator from the cylinder block sub-assembly.
      GTY931758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
scientia non olet · About LEMON Manuals