Engine Assembly Removal

Remove the console box (RAV4_ACA30 RM000001RHJ00GX_01_0039.html).

Disconnect the connector.

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

HINT:

DTC P0171 (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_01_0010.html).

Remove the engine hood (RAV4_ACA30 RM00000161Z00KX_01_0006.html).

Loosen the bolt, nut and remove the battery clamp.

Remove the battery.

Remove the 2 nuts and 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 cylinder block drain cock plug.

Drain automatic transaxle fluid for U241E (2WD) (RAV4_ACA30 RM000001SU1018X_01_0002.html).

Drain automatic transaxle fluid for U140F (4WD) (RAV4_ACA30 RM000001SU1016X_01_0002.html).

Drain transaxle oil for E352 (2WD) (RAV4_ACA30 RM000001YVO00BX_01_0015.html).

Drain transaxle oil for E359F (4WD) (RAV4_ACA30 RM000001YVO00AX_01_0015.html).

Remove the radiator (RAV4_ACA30 RM000001X9G00NX.html).

Remove the 2 bolts and reservoir.

Disconnect the purge VSV connector.

Disconnect the wire harness clamp.

Disconnect the 2 purge line hoses from the purge VSV.

Remove the purge VSV from the air cleaner hose.

Disconnect the mass air flow meter connector.

Disconnect the purge VSV connector.

Disconnect the 4 wire harness clamps.

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

Disconnect the purge line hose from the clamp.

Lock the No. 1 air cleaner hose clamp, and then disconnect the No. 1 air cleaner hose from the throttle body.

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

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

Remove the 3 bolts.

Disconnect the case from the No. 1 air cleaner inlet.

Disconnect the 2 clamps of the engine wire.

Remove the 4 bolts and front battery carrier.

Remove the 2 bolts and battery bracket reinforcement.

Remove the 2 bolts, nut and battery carrier bracket.

Disconnect the 2 union to connector tube hoses from the booster vacuum tube.

Disconnect the union to connector tube hose from the booster vacuum tube.

Disconnect the heater water inlet hose from the heater unit.

Disconnect the heater water outlet hose from the heater unit.

Remove the fuel tube from the fuel hose clamp.

Remove the fuel pipe clamp.

Wipe off any dirt on the fuel tube connector.

Hold the fuel tube connector, and then install the SST.

SST

09268-21010

Turn the SST to align the retainer inside the fuel tube connector with the chamfered part of the SST.

Insert the SST into the fuel tube and hold it. Then push the fuel tube connector toward the SST side.

Mount the retainer of the fuel tube connector onto the chamfered part of the SST.

Slide the SST and fuel tube connector together towards the fuel tube until they make a "click" sound, and then disconnect the fuel tube.

Drain the fuel remaining inside the fuel tube.

Cover the fuel tube and fuel pipe with a plastic bag to protect the disconnected part.

Disconnect the No. 2 ventilation hose from the ventilation valve.

Disconnect the purge line hose from the throttle body.

Disconnect the water by-pass hose from the throttle body.

Disconnect the No. 2 water by-pass hose from the throttle body.

for Type A:
Disconnect the No. 1 throttle body hose from the throttle body.

Disconnect the throttle position sensor and control motor connector.

Disconnect the wire harness clamp.

Disconnect the fuel tube from the clamp.

Remove the 4 bolts, and then remove the fuel pipe support and throttle body.

Remove the gasket from the intake manifold.

Remove the 2 wire harness clamps.

Disconnect the 4 fuel injector connectors.

Remove the 2 bolts and then pull out the fuel delivery pipe together with the 4 fuel injectors.

NOTICE:

Be careful not to drop the fuel injectors when removing the fuel delivery pipe.

Remove the 2 delivery pipe spacers from the cylinder head.

Remove the 4 insulators from the cylinder head.

Disconnect the union to check valve hose from the brake booster.

Disconnect the camshaft timing oil control valve connector.

Remove the wire harness clamp.

Remove the union to check valve hose from the vacuum hose clamp.

Remove the 5 bolts, 2 nuts and intake manifold.

Remove the gasket from the intake manifold.

Remove the intake manifold insulator from the cylinder block.

Remove the transaxle control cable for U241E (2WD) (RAV4_ACA30 RM000001SU600WX_01_0004.html).

Remove the transaxle control cable for U140F (4WD) (RAV4_ACA30 RM000001SU600UX_01_0004.html).

Remove the transaxle control cable for E352 (2WD) (RAV4_ACA30 RM000001YVD008X_01_0004.html).

Remove the transaxle control cable for E359F (4WD) (RAV4_ACA30 RM000001YVD007X_01_0004.html).

Remove the clutch release cylinder for E352 (2WD) (RAV4_ACA30 RM000001YVO00BX_01_0007.html).

Remove the clutch release cylinder for E359F (4WD) (RAV4_ACA30 RM000001YVO00AX_01_0007.html).

Remove the 4 bolts and reinforcement RH.

Using SST and 19 mm socket wrench, loosen the V-ribbed belt tensioner arm clockwise, then remove the fan and generator V belt.

SST

09216-42010

NOTICE:

1. Be sure to connect SST and the tools so that they are in line during use.
   
2. When retracting the tensioner, turn it clockwise slowly for 3 seconds or more. Do not apply force rapidly.
   
3. After the tensioner is fully retracted, do not apply force any more than necessary.
   

Disconnect the generator connector.

Remove the terminal cap.

Remove the nut and disconnect the generator wire.

Remove the bolt and wire harness clamp bracket.

Remove the wire harness clamps.

Remove the 2 bolts and generator.

Remove the cooler compressor (RAV4_ACA30 RM000001801020X_01_0007.html).

HINT:

Disconnect the compressor together with the low-pressure and high-pressure hoses, then secure it to the vehicle side using rope.

Remove the ECM (RAV4_ACA30 RM0000017UO01HX_01_0003.html).

Remove the engine room relay block cover.

Remove the nut and disconnect the 2 engine wire connectors.

Remove the bolt and disconnect the engine wire cover clamp.

Disconnect the ground cable connector.

Remove the nut from the battery positive (+) terminal to disconnect the engine wire.

Disconnect the ground cable engine wire clamp located near the starter.

Remove the bolt and ground cable located near the starter.

Remove the 2 bolts, 2 compression springs and front exhaust pipe.

Remove the gasket from the exhaust manifold.

Remove the front drive shaft (for 2WD) (RAV4_ACA30 RM00000226L014X.html).

Remove the front drive shaft (for 4WD) (RAV4_ACA30 RM00000226Q008X.html).

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 through bolt and nut.

Remove the 2 bolts and front engine mounting insulator FR.

Remove the through bolt.

Remove the 2 nuts, 2 bolts and engine mounting insulator RR.

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

Torque:

38 N*m{387 kgf*cm, 28 ft.*lbf}

Part No.:

Item	Part No.
No. 1 engine hanger	12281-28010
No. 2 engine hanger	12282-28010
Bolt	91512-61020

Attach the sling device and the engine with the chain block.

Carefully remove the engine with transaxle from the vehicle.

Remove the 2 nuts, 4 bolts and engine mounting insulator RH.

Remove the through bolt and nut.

Remove the 4 bolts and engine mounting insulator LH.

Remove the 3 bolts and bracket.

Remove the 3 bolts and bracket.

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

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

Remove the starter for 1.6 kW Type (RAV4_ACA30 RM000000YQ400SX_01_0007.html).

Remove the starter for 1.7 kW Type (RAV4_ACA30 RM000000YQ400TX_01_0007.html).

Remove the automatic transaxle for U241E (2WD) (RAV4_ACA30 RM000001SUM00ZX_01_0005.html).

Remove the automatic transaxle for U140F (4WD) (RAV4_ACA30 RM000001SUM00XX_01_0005.html).

Using SST, hold the crankshaft.

SST

09213-54015(91651-60855)
09330-00021

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

Remove the 2 bolts and insulator from the stiffener plate.

Remove the 4 bolts and stiffener plate.

Remove the 4 bolts and stiffener plate.

Remove the manual transaxle for E352 (2WD) (RAV4_ACA30 RM000001YVO00BX_01_0012.html).

Remove the manual transaxle for E359F (4WD) (RAV4_ACA30 RM000001YVO00AX_01_0012.html).

Put matchmarks on the clutch cover assembly and flywheel sub-assembly.

Loosen each set bolt one turn at a time in the order shown in the illustration until the spring tension is released.

Remove the set bolts and pull off the clutch cover assembly.

NOTICE:

Do not drop the clutch disc assembly.

Using SST, hold the crankshaft.

SST

09213-54015(91651-60855)
09330-00021

Remove the 8 bolts and flywheel.