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Home >> Toyota >> 2022 >> RAV4 LE, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 157 (Engine Mechanical System (A25A-FXS) - Service Information (5 Of 6)) >> Engine Unit >> Installation [12/2021 - ] >> Procedure

Installation [12/2021 - ]: Procedure

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

  2. 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.
  3. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  4. INSTALL FUEL INJECTOR SEAL 

    Refer to PROCEDURE - Step 1

  5. INSTALL DIRECT FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  6. INSTALL FUEL DELIVERY PIPE 

    Refer to PROCEDURE - Step 3

  7. INSTALL PORT FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  8. INSTALL NO. 5 ENGINE WIRE 

    Refer to PROCEDURE - Step 2

  9. INSTALL INJECTOR VIBRATION INSULATOR 

    Refer to PROCEDURE - Step 3

  10. INSTALL NO. 1 DELIVERY PIPE SPACER 

    Refer to PROCEDURE - Step 4

  11. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  12. 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) 

  13. 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.
  14. 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.
  15. INSTALL NO. 7 WATER BY-PASS HOSE 
    1. Install the No. 7 water by-pass hose and slide the 2 clips to secure them.
  16. TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) 

    Refer to PROCEDURE - Step 1

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

    Refer to PROCEDURE - Step 2

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

    Refer to PROCEDURE - Step 3

  19. 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) 

  20. CONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  21. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET 

    Refer to PROCEDURE - Step 3

  22. INSTALL INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 4

  23. INSTALL NO. 2 WATER BY-PASS PIPE 
    1. Install the bolt (A).
      GTY1002387Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    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) 

  24. 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) 

  25. 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.

  26. 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.
  27. INSTALL EGR COOLER ASSEMBLY 
    1. Install a new EGR cooler gasket to the EGR cooler assembly.
      NOTE:

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

      GTY1001304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Claw
    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 Bolts And Nuts Tightening Sequence (Type A)
        GTY1001222Courtesy 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:
      Fig 2: EGR Cooler Assembly Bolts And Nuts Tightening Sequence (Type B)
      GTY1001331Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
      1. Temporarily install the EGR cooler assembly to the cylinder head sub-assembly and EGR valve assembly with the 3 bolts and 2 nuts.
      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 and slide the clip to secure it.
    6. Connect the No. 4 water by-pass hose to the EGR cooler assembly and slide the clip to secure it.
  28. INSTALL EGR VALVE ASSEMBLY 
    1. Using an 8 mm socket wrench, install the EGR valve assembly to the camshaft housing sub-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.
  29. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  30. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  31. INSTALL EXHAUST MANIFOLD 

    Refer to PROCEDURE - Step 2

  32. INSTALL MANIFOLD STAY 

    Refer to PROCEDURE - Step 3

  33. 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
  34. INSTALL FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY) 
    1. Install the water hose clamp bracket with the 2 bolts as shown in the illustration.

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

      GTY742778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Temporarily install the bolt (A), and then tighten the 2 bolts in the order of (B) and (A).

    2. 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.
      GTY915205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
      *b 90° (Claw of Clip Location)
      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.
    3. Connect the flow shutting valve (water by-pass hose assembly) with the bolt.

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

  35. 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.
  36. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY 
    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 bolt and 2 nuts.
      GTY769374Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut

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

      HINT: 

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

  37. 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) 

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