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Home >> Toyota >> 2025 >> RAV4 Plug-In Hybrid SE >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Intake / Exhaust System (A25A-FXS) - Service Information (PHEV) >> Intake Manifold >> Removal [06/2020 - ] >> Procedure

Removal [06/2020 - ]: Procedure

  1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 

    Refer to PROCEDURE - Step 3

  2. REMOVE SUCTION HOSE SUB-ASSEMBLY 
    1. Remove the 2 bolts and suction hose sub-assembly.
      GTY996836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not apply excessive force to the suction hose sub-assembly.

    2. Remove the 2 O-rings from the suction hose sub-assembly.
      NOTE:

      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.

  3. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to REMOVAL [06/2020 - ]

  4. REMOVE EGR VALVE ASSEMBLY 

    Refer to REMOVAL [06/2020 - 12/2021] , or refer to REMOVAL [12/2021 - 10/2022] , or refer to REMOVAL [10/2022 - ]

  5. REMOVE E.F.I. VACUUM SENSOR ASSEMBLY (MANIFOLD ABSOLUTE PRESSURE SENSOR) 

    Refer to PROCEDURE - Step 1

  6. REMOVE PURGE VALVE (PURGE VSV) 

    Refer to PROCEDURE - Step 1

  7. DISCONNECT ENGINE WIRE 
    1. Disconnect the No. 5 engine wire connector.
      GTY763895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and disconnect the engine wire from the cylinder head sub-assembly.
    3. Remove the bolt.
      GTY915002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Detach the wire harness clamp and disconnect the engine wire from the intake manifold.
  8. DISCONNECT NO. 3 WATER BY-PASS PIPE 
    1. Slide the clip and disconnect the No. 5 water by-pass hose from the No. 3 water by-pass pipe.
      GTY754164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an 8 mm socket wrench, remove the bolt and disconnect the No. 3 water by-pass pipe from the intake manifold.
  9. REMOVE NO. 2 WATER BY-PASS PIPE 
    1. Detach the wire harness clamp and disconnect the HV air conditioning wire.
      GTY742337Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an 8 mm socket wrench, remove the 2 bolts (A) and separate the No. 2 water by-pass pipe from the intake manifold.
    3. Remove the bolt (B) and No. 2 water by-pass pipe from the cylinder block sub-assembly.
  10. REMOVE NO. 2 FUEL VAPOR FEED HOSE 
    1. Remove the No. 2 fuel vapor feed hose from the intake manifold.
      GTY771529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE INTAKE MANIFOLD 
    1. GTY943117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      w/o Stud Bolt:

      1. Remove the 5 bolts and intake manifold from the cylinder head sub-assembly.
    2. w/ Stud Bolt:
      GTY865114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
      1. Remove the 3 bolts, 2 nuts and intake manifold from the cylinder head sub-assembly.
  12. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET 
    1. Remove the No. 1 intake manifold to head gasket from the intake manifold.
      GTY754160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE NO. 1 ENGINE COVER 
    1. Remove the clip and No. 1 engine cover.
      GTY771528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE VACUUM HOSE 
    1. Remove the vacuum hose from the intake manifold.
      GTY754161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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