Engine Assembly Removal

Start the engine.

Turn the A/C switch on.

Operate the cooler compressor while the engine speed is approximately 1000 rpm for 5 to 6 minutes to circulate the refrigerant and collect the compressor oil remaining in each component into the cooler compressor.

Stop the engine.

Recover the refrigerant from the A/C system using a refrigerant recovery unit.

SST

09985-20010(09985-02130,09985-02150,09985-02090,09985-02110,09985-02010,09985-02050,09985-02060,09985-02070)

Remove the console box (RAV4_ACA30 RM000001RHJ00GX.html).

Start the engine. After the engine has stopped, turn the ignition switch off.

HINT:

DTC P0171/P0172 (system too lean) may be set.

Check that the engine does not start.

Remove the fuel tank cap, and let the air out of the fuel tank.

Connect the connector.

Install the console box (RAV4_ACA30 RM000001RHG00HX.html).

Remove the 2 bolts, 4 screw, 10 clips and under cover.

Remove the 2 clips and under cover.

Remove the 2 clips and under cover.

Remove the 2 clips and under cover.

Loosen the radiator drain cock plug.

HINT:

Collect the coolant in a container and dispose of it according to the regulations in your area.

Remove the radiator reservoir cap.

CAUTION:

Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

Loosen the 2 cylinder block drain cock plugs.

Remove the oil filler cap.

Remove the oil drain plug and gasket, and drain the engine oil into a container.

Remove the drain plug and gasket, and drain the ATF.

Install a new gasket and the drain plug.

Torque:

49 N*m{500 kgf*cm, 36 ft.*lbf}

Remove the drain plug and gasket, and drain the oil.

Install a new gasket and the drain plug.

Torque:

39 N*m{398 kgf*cm, 28 ft.*lbf}

Remove the hood sub-assembly (RAV4_ACA30 RM00000161Z00KX.html).

Detach the 3 clips and remove the V-bank cover.

Remove the 9 clips and cover.

Remove the bolt and loosen the nut.

Detach the 2 wire harness clamps.

Detach the hook of the battery clamp from the front battery bracket, and then remove the battery clamp.

Remove the battery and battery insulator.

Detach the 2 wire harness clamps.

Remove the 4 bolts and front bracket.

Remove the 2 bolts and bracket reinforcement.

Disconnect the mass air flow meter connector.

Disconnect the VSV (air intake control) connector.

Disconnect the 2 wire harness clamps and 2 vacuum hoses.

Disconnect the No. 2 ventilation hose from the air cleaner hose.

Loosen the No. 1 air cleaner hose clamp.

Unfasten the 2 hook clamps, and then remove the air cleaner cap.

Remove the air cleaner filter element from the air cleaner case.

Disconnect the harness clamp.

Remove the 3 bolts and air cleaner case.

Remove the 3 bolts of the ECM bracket.

Disconnect the 2 ECM connectors.

NOTICE:

After disconnecting the connector, make sure that dirt, water and other foreign matter does not contact the connecting part of the connector.

1. Push the locks on the 2 levers, then raise the levers, and disconnect the 2 ECM connectors.
   

Remove the ECM with bracket.

Remove the 4 screws and 2 ECM brackets.

Remove the engine room junction block cover upper.

Disconnect the engine wire from the engine room junction block.

1. Remove the bolt and disconnect the 4 clamps.
   





2. Remove the nut and disconnect the 3 engine wire connectors.
   





3. Using a screwdriver, unlock the engine room junction block. Pull the engine room junction block upward.
   

4. Remove the nut and disconnect the starter wire.
   

Remove the No. 1 fuel pipe clamp.

Disconnect the connector from the tube while pinching part A with your fingers as shown in the illustration.

NOTICE:

1. Check for contamination in the pipe and around the connector. Clean if necessary and then disconnect the connector.
   
2. Disconnect the connector by hand.
   
3. Do not bend, kink or twist the nylon tube.
   
4. If the pipe and connector are stuck together, push and pull on the connector to release them.
   
5. Put the pipe and connector ends in vinyl bags to prevent damage and contamination.
   

Disconnect the heater inlet water hose.

Disconnect the heater outlet water hose.

Remove the 2 bolts, 2 hoses and reservoir tank.

Remove the clamp and disconnect the No. 1 fuel vapor feed hose.

Disconnect the union to check valve hose.

Remove the bolt and disconnect the cooler refrigerant suction hose from the cooler compressor.

Remove the O-ring from the cooler refrigerant suction hose.

NOTICE:

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

Remove the bolt and disconnect the cooler refrigerant discharge hose from the cooler compressor.

Remove the O-ring from the cooler refrigerant discharge hose.

NOTICE:

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

Remove the clamp and disconnect the radiator hose inlet.

Remove the clamp and disconnect the radiator hose outlet.

Disconnect the 2 hoses from the transmission oil filler tube and oil cooler tube.

Disconnect the transmission control cable assembly (RAV4_ACA30 RM000001SU600VX.html).

Remove the heated oxygen sensor (RAV4_ACA30 RM000001ROP00PX.html).

Remove the No. 2 exhaust pipe sub-assembly (RAV4_ACA30 RM00000252S007X.html).

Remove the 2 bolts, 2 nuts, and center exhaust pipe assembly.

Remove the 2 gaskets.

Remove the 2 bolts and No. 1 exhaust pipe support bracket.

Remove the 2 nuts and front exhaust pipe assembly.

Remove the gasket from the exhaust manifold.

Remove the 2 bolts and 2 adjusting washers, and disconnect the propeller with center bearing shaft.

NOTICE:

1. During the removal, do not exert excessive force on the universal joint.
   
2. When removing, transporting or storing the propeller with center bearing shaft assembly, do not allow the No. 2 joint angle to exceed 20°.
   

Place matchmarks on the differential carrier and propeller shaft.

Remove the 4 nuts and 4 washers, and disconnect the propeller shaft and differential carrier.

Place matchmarks on the transfer and propeller shaft.

Remove the 4 nuts and 4 washers, and disconnect the propeller shaft from the transfer.

Remove the front drive shaft LH (RAV4_ACA30 RM00000226Q008X.html).

Remove the front drive shaft RH (RAV4_ACA30 RM00000226Q008X.html).

Turn back the floor carpet and remove the 2 clips and silencer sheet.

Use a seat belt to fix the steering wheel in place to avoid breakage of the spiral cable.

Place matchmarks on the No. 2 steering intermediate shaft and steering intermediate shaft.

Remove the bolt and disconnect the No. 2 steering intermediate shaft.

Remove the clip A, detach the clip B from the body and disconnect the No. 1 steering column hole cover.

NOTICE:

Do not damage clips A and B.

Remove the cotter pin and castle nut.

Using SST, disconnect the tie rod end from the steering knuckle.

SST

09628-62011

NOTICE:

Do not damage the tie rod end dust cover.

Remove the bolt, 2 nuts and No. 2 engine mounting stay RH.

Install the No. 1 and No. 2 engine hangers with the 4 bolts as shown in the illustration.

Torque:

33 N*m{337 kgf*cm, 24 ft.*lbf}

HINT:

1. Insert the claw of the hanger into hole of the cylinder head.
   
2. Fit the fork part of the hanger onto the rib of the cylinder head.
   

Install an engine sling device to the engine and hold the engine with a chain block.

CAUTION:

Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

Set an engine lifter underneath the engine.

Remove the 2 bolts and 2 nuts, and disconnect the engine mounting insulator RH.

Remove the bolt and nut, and disconnect the engine mounting insulator LH.

Remove the 6 bolts and front suspension member brace rear RH and LH.

Remove the 6 bolts, crossmember and suspension member.

Using the chain block, slowly remove the engine from the vehicle and the intermediate shaft from the pinion. Then set the engine on the engine lifter.

NOTICE:

1. Make sure that the engine is clear of all wiring and hoses.
   
2. While lowering the engine from the vehicle, do not allow it to contact the vehicle.
   

HINT:

Place the engine on wooden blocks or equivalent so that the engine is level.

Remove the bolt, nut and crossmember.

Remove the bolt and suspension crossmember.

Remove the engine wire from the engine.

Disconnect the starter connector.

Open the terminal cap, remove the nut and disconnect the starter wire.

Remove the 2 bolts and starter.

Remove the 2 bolts and flywheel housing under cover.

Turn the crankshaft to gain access and remove the 6 bolts while holding the crankshaft pulley bolt with a wrench.

Remove the 3 lower side mounting bolts.

Remove the 7 upper side mounting bolts.

Separate and remove the automatic transaxle.

except K111F:
Remove the 6 nuts, 2 bolts and transfer from the transaxle.

for K111F:
Remove the 6 nuts and transfer from the transaxle.

Using SST, hold the crankshaft.

SST

09213-70011(09213-70020)
09330-00021

Remove the 8 bolts, front spacer, drive plate and rear spacer.

NOTICE:

Do not reuse the bolts.

Install the engine to an engine stand. Remove the sling device and chain block from the engine.

Disconnect the 2 water by-pass hoses from the throttle body.

Disconnect the vapor feed hose.

Disconnect the throttle body connector and clamp.

Disconnect the connector.

Disconnect the No. 1 ventilation hose and vacuum hose.

Remove the 2 bolts and throttle body bracket.

Remove the 2 bolts and No. 1 surge tank stay.

Using a 5 mm socket hexagon wrench, remove the 4 bolts.

Remove the 2 nuts and surge tank.

Remove the gasket from the surge tank.

Remove the 6 bolts and 6 coils from the cylinder head.

Remove the bolt and mounting stay.

Remove the 6 bolts, 4 nuts, intake manifold and 2 gaskets.

Remove the 2 bolts, nut and manifold stay.

Disconnect the air fuel ratio sensor connector clamp.

Uniformly loosen and remove the 6 nuts.

Remove the manifold and gasket.

Rotate the tensioner pulley counterclockwise to loosen the belt tension. Then remove the V-ribbed belt.

While turning the belt tensioner counterclockwise, align its holes, and then insert a 5 mm bi-hexagon wrench into the holes to fix the V-ribbed belt tensioner in place.

Remove the bolt, No. 2 idler pulley cover plate, idler pulley and idler pulley cover plate.

Disconnect the connector.

Remove the 4 bolts and cooler compressor.

Disconnect the 2 wire harness clamps.

Remove the terminal cap.

Remove the nut and disconnect the generator wire from terminal B.

Disconnect the generator connector from the generator.

Remove the bolt from the cylinder block.

Remove the 2 bolts and generator.

Remove the dipstick.

Remove the 2 bolts, and the No. 1 and No. 2 guides.

Remove the O-rings from the guide.

Remove the bolt, nut and manifold stay.

Remove the 3 bolts and insulator.

Uniformly loosen and remove the 6 nuts.

Remove the manifold and gasket.

Remove the 3 bolts and drive shaft bearing bracket.

Remove the 5 bolts and V-ribbed belt tensioner assembly.

Remove the 2 bolts and gear cover.

Using SST, hold the water pump pulley.

SST

09960-10010(09962-01000,09963-00700)

Remove the 4 bolts and water pump pulley.

Remove the 2 bolts and 2 radio setting condensers.

Remove the bolt and No. 1 vacuum switching valve.

Using a 24 mm deep socket wrench, remove the pressure switch.

Disconnect the 2 sensor connectors.

Remove the 2 bolts and 2 sensors.

Using a 19 mm deep socket wrench, remove the sensor and gasket.