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Home >> Toyota >> 2025 >> RAV4 Plug-In Hybrid SE >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical System (A25A-FXS) - Service Information (2 Of 3) (PHEV) >> Engine Assembly >> Removal [06/2020 - 12/2021] >> Procedure

Removal [06/2020 - 12/2021]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the ignition 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 [06/2020 - ]

  2. REMOVE DECK BOARD ASSEMBLY 

    Refer to PROCEDURE - Step 2

  3. REMOVE BATTERY HOLE COVER 

    Refer to PROCEDURE - Step 3

  4. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL 

    Refer to PROCEDURE - Step 4

  5. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL [06/2020 - 12/2021]

  6. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 

    Refer to PROCEDURE - Step 1

  7. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [06/2020 - ]

  8. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  9. SECURE STEERING WHEEL 

    Refer to PROCEDURE - Step 3

  10. REMOVE FRONT WHEELS 

    Refer to REMOVAL [06/2020 - ]

  11. REMOVE FRONT FENDER FRONT SPLASH SHIELD LH 
    1. Remove the 4 screws.
      GTY997634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the clip and remove the front fender front splash shield LH.
  12. REMOVE FRONT FENDER FRONT SPLASH SHIELD RH 
    1. Remove the 4 screws.
      GTY997627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the clip and remove the front fender front splash shield RH.
  13. REMOVE NO. 1 ENGINE UNDER COVER 
    1. Remove the 2 bolts and 6 screws.
    2. Detach the guide and remove the No. 1 engine under cover.
      GTY1000197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt Screw
  14. REMOVE NO. 2 ENGINE UNDER COVER ASSEMBLY 
    1. Remove the 2 bolts, screw, 7 clips and No. 2 engine under cover assembly.
      GTY997734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
      Clip
  15. 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
  16. 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
  17. REMOVE ACCUMULATOR ASSEMBLY 

    Refer to REMOVAL [06/2020 - ]

  18. REMOVE FRONT LOWER BUMPER ABSORBER 
    1. Remove the clip.
      GTY997644Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the claws and remove the front lower bumper absorber.
  19. REMOVE FRONT BUMPER NO. 2 REINFORCEMENT 

    Refer to PROCEDURE - Step 37

  20. DRAIN ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 1

  21. DRAIN ENGINE OIL 

    Refer to PROCEDURE - Step 2

  22. DRAIN HYBRID TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 6

  23. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. GTY1000918Courtesy 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.

  24. REMOVE INLET AIR CLEANER ASSEMBLY 

    Refer to PROCEDURE - Step 3

  25. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 4

  26. REMOVE HYBRID MOTOR CONTROL INVERTER ASSEMBLY 

    Refer to REMOVAL [06/2020 - 12/2021]

  27. REMOVE DISCHARGE HOSE SUB-ASSEMBLY 
    1. Remove the 2 bolts, nut and discharge hose sub-assembly.
      GTY1000610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt A
      Bolt B
      Nut
      NOTE:

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

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

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

  28. REMOVE NO. 3 COOLER BRACKET 
    1. Remove the nut and No. 3 cooler bracket.
      GTY997650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE INVERTER RESERVE TANK SUB-ASSEMBLY 
    1. Remove the 2 bolts.
      GTY997375Courtesy 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 sub-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 sub-assembly.
  30. REMOVE SUCTION HOSE SUB-ASSEMBLY 
    1. Remove the bolt and remove the suction hose sub-assembly.
      GTY997647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

    2. Remove the O-ring 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.

  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.
      GTY997666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE 
    1. Detach the clamp.
      GTY997667Courtesy 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 [06/2020 - ]

      GTY1000910Courtesy 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 [06/2020 - ]

        GTY1000908Courtesy 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.
      GTY1001032Courtesy 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).
      GTY1000297Courtesy 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.
      GTY997895Courtesy 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.
      GTY997896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. DISCONNECT NO. 5 INVERTER COOLING HOSE 
    1. Slide the clip and disconnect the No. 5 inverter cooling hose from the motor cooling cooler.
      GTY997901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. DISCONNECT NO. 1 TRANSMISSION OIL COOLER HOSE ASSEMBLY 
    1. Slide the clip and disconnect the No. 1 transmission oil cooler hose assembly from the oil cooler assembly. (Inlet Side)
      GTY997256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clip and disconnect the No. 1 transmission oil cooler hose assembly from the oil cooler assembly. (Outlet Side)
      GTY997257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. 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.
      GTY997909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connectors from the engine room relay block and junction block assembly.
      GTY997910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, detach the claw and disconnect the wire harness from the engine room relay block and junction block assembly.
    4. Detach the clamp.
      GTY997907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the bolt and disconnect the ground wires.
  41. DISCONNECT FLOOR UNDER WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Using a screwdriver, slide the green-colored lock of the connector as shown in the illustration to release it and disconnect the HV floor under wire.
      GTY997440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Green-colored Lock
      Slide
  42. REMOVE FRONT FLOOR COVER LH 
    1. Remove the 2 bolts, screw and 7 clips.
      GTY1000860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
      Clip
    2. Detach the clips and remove the front floor cover LH.
  43. REMOVE FRONT FLOOR COVER RH 
    1. Remove the 2 bolts, 3 screws and clip.
      GTY997761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
      Clip
    2. Detach the clips and remove the front floor cover RH.
  44. REMOVE ENGINE UNDER COVER HEAT INSULATOR 
    1. Using the service plug grip, remove the No. 23 traction battery bracket.

      HINT: 

      Insert the projection of the service plug grip and turn the button of the No. 23 traction battery bracket counterclockwise to release the lock.

      GTY995908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Service Plug Grip
      *2 No. 23 Traction Battery Bracket
      *a Projection
      *b Turn
      *c Button
    2. Remove the 2 bolts, 2 nuts and engine under cover heat insulator.
      GTY998276Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
  45. REMOVE FRONT EXHAUST PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 3

  46. REMOVE FRONT AXLE SHAFT NUT LH 

    Refer to PROCEDURE - Step 4

  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 5

  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 9

  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 14

  57. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH 

    Refer to PROCEDURE - Step 15

  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.
      GTY998032Courtesy 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.
      GTY997261Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    3. Remove the 4 bolts and the engine mounting stay LH from the engine mounting insulator sub-assembly LH.
      GTY997914Courtesy 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.
      GTY997919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. 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.
      GTY997372Courtesy 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
    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.
      GTY997931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. REMOVE FRONT ENGINE SUPPORT MEMBER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 8

  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 15

  65. REMOVE WIRING HARNESS CLAMP BRACKET 
    1. Detach the clamps and disconnect the engine wire.
      GTY1000905Courtesy 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. GTY1001029Courtesy 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.
      GTY997930Courtesy 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 2 bolts.
      GTY997723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Detach the guide to remove the HV air conditioning wire from the hybrid vehicle transaxle assembly.
  69. REMOVE OIL PUMP WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 7

  70. REMOVE FLYWHEEL HOUSING SIDE COVER 

    Refer to PROCEDURE - Step 13

  71. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY 

    Refer to PROCEDURE - Step 19

  72. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY 

    Refer to PROCEDURE - Step 2

  73. REMOVE FLYWHEEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  74. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE 

    Refer to PROCEDURE - 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.
      GTY997227Courtesy 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. Remove the bolt and disconnect the air conditioning tube and accessory assembly.
      GTY997717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and nut.
      GTY997890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    3. Disconnect the No. 6 water by-pass hose, connectors and detach the clamps.
      GTY997811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      No. 6 Water By-pass Hose
      Connector
      Remove in this Direction
    4. Remove the radiator reserve tank assembly as shown in the illustration.
    5. Remove the bolt and disconnect the No. 2 ground wire.
      GTY997737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 2 bolts and nut and remove the engine mounting insulator sub-assembly RH.
      GTY998007Courtesy 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. Remove the 2 bolts and engine mounting spacer from the vehicle body.
      GTY997743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  80. 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 2 bolts, nut and the engine mounting insulator sub-assembly LH.
      GTY998241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
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