Engine Assembly Removal

Discharge fuel system pressure (RAV4_ACA30 RM000001EEY01OX.html).

Remove the 9 clips and radiator support opening cover.

Remove the 6 screws, 10 clips and under cover.

Remove the 3 clips and under cover.

Remove the 2 clips and under cover.

Remove the 3 clips and under cover.

Remove the nut, bolt, 3 clips and floor cover.

Install a vinyl hose to the drain cock plug on the radiator side.

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 water drain cock plug.

Remove the oil filler cap.

Remove the 2 clips and open the oil pan drain service cover.

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

Remove the filler plug and gasket.

Remove the drain plug and gasket to drain the manual transaxle oil.

Install a new gasket and the drain plug.

Torque:

39 N*m{400 kgf*cm, 29 ft.*lbf}

Using a 6 mm socket hexagon wrench, remove the overflow plug and gasket from the continuously variable transaxle assembly.

Using a 6 mm socket hexagon wrench, remove the No. 1 transmission oil filler tube from the continuously variable transaxle assembly and drain the continuously variable transaxle fluid.

Using a 6 mm socket hexagon wrench, install the No. 1 transmission oil filler tube to the continuously variable transaxle assembly.

Torque:

1.7 N*m{17 kgf*cm, 15 in.*lbf}

Temporarily install the gasket and overflow plug.

HINT:

Reuse the old gasket. The plug will be removed again to adjust the fluid level.

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}

Hold the rear of the cover and raise it to detach the 2 clips on the rear of the cover. Continue to raise the cover to detach the 2 clips on the front of the cover and remove the cover.

NOTICE:

Attempting to detach both front and rear clips at the same time may cause the cover to break.

Disconnect the No. 1 and No. 2 water by-pass hoses.

Remove the 2 bolts and radiator reservoir.

Loosen bolts A and B.

Loosen bolt C and remove the V-ribbed belt.

NOTICE:

Do not loosen bolt D.

Remove the terminal cap.

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

Disconnect the connector and wire harness clamp.

Loosen the 3 bolts.

Remove the 2 bolts and adjusting bar.

Remove the bolt and generator.

Remove the bolt and wire harness clamp bracket.

Disconnect the radiator hose from the water inlet.

Disconnect the connector.

Remove the 2 bolts and 2 nuts.

Using an E8 "TORX" socket wrench, remove the 2 stud bolts and disconnect the compressor with pulley assembly.

HINT:

It is not necessary to completely remove the compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.

Remove the bolt and loosen the nut.

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

Detach the 3 wire harness clamps.

Remove the 4 bolts, disconnect the No. 3 engine wire and remove the front battery bracket.

Remove the 2 bolts and battery bracket reinforcement.

Disconnect the mass air flow meter connector.

Detach the clamp.

Disconnect the No. 2 ventilation hose from the cylinder head cover.

Squeeze the taps of the air cleaner hose clamp, and then disconnect the air cleaner hose from the throttle body.

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

Disconnect the wire harness clamp from the air cleaner case.

Remove the 3 bolts and air cleaner case.

Remove the 3 bolts of the ECM with brackets.

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. Raise the 2 levers while pushing the locks on the 2 levers, and disconnect the 2 ECM connectors.
   

Remove the ECM with brackets.

Remove the 4 screws and 2 ECM brackets.

Disconnect the radiator hose from the cylinder head.

Remove the No. 1 fuel pipe clamp.

Pinch the tube connector and then pull the fuel tube connector off of the fuel pipe.

NOTICE:

1. Check for foreign matter in the fuel tube around the fuel tube connector. Clean it if necessary. Foreign matter can affect the ability of the O-ring to seal the connector and fuel main tube.
   
2. Do not use any tools to separate the connector and pipe.
   
3. Do not forcefully bend, kink or twist the hose.
   
4. Keep the connector and pipe free from foreign matter.
   
5. If the connector and pipe are stuck together, pinch the connector and turn it carefully to disconnect it.
   
6. Put the connector in a plastic bag to prevent damage and contamination.
   

Remove the bolt. Then disconnect the 3 clamps and engine wire.

Remove the nut and disconnect the engine wire.

Disconnect the 3 relay block connectors.

Remove the bolt. Then disconnect the clamp and ground wire.

Disconnect the connector tube hose.

Disconnect the 2 heater hoses.

Removal the 2 clips and washers, and disconnect the top ends of the control cable from the transaxle.

Remove the 2 clips and disconnect the control cable from the control cable bracket.

Remove the nut and disconnect the control cable from the control shaft lever.

Remove the clip and disconnect the transmission control cable from the control cable bracket.

Disconnect the control cable from the control cable support.

Remove the bolt and disconnect the clamp of the control cable.

Using a 10 mm union nut wrench, disconnect the clutch hose from the flexible hose tube.

Remove the clip and disconnect the clutch hose.

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.

Using SST and a hammer, unstake the staked part of the nut.

SST

09930-00010

NOTICE:

Loosen the staked part of the nut completely, otherwise the screw of the drive shaft may be damaged.

While applying the brakes, remove the lock axle hub nut.

Remove the front axle hub sub-assembly LH (RAV4_ACA30 RM00000227J00IX.html).

for 2WD:
Remove the front drive shafts (RAV4_ACA30 RM00000226L014X_01_0019.html).

for 4WD:
Remove the front drive shafts (RAV4_ACA30 RM00000226Q008X_02_0019.html).

Remove the 2 bolts and disconnect the front exhaust pipe from the center exhaust pipe.

Remove the gasket from the exhaust pipe.

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

Disconnect the grommet from the floor panel.

Using SST, loosen the sensor, and then disconnect the sensor by hand.

SST

09224-00010

HINT:

Rotate the sensor counterclockwise to disconnect it from the front exhaust pipe, and record how many times it is rotated.

NOTICE:

Do not strike the metal part of the sensor.

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 flywheel housing under cover.

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

Remove the 4 bolts and reinforcement.

Remove the 4 bolts and reinforcement.

Remove the 6 bolts and crossmember.

Remove the bolt, nut and engine mounting insulator.

Set an engine lifter underneath the engine.

HINT:

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

Remove the bolt 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 2 bolts and front suspension crossmember.

Operate the engine lifter and slowly remove the engine from the vehicle.

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.
   

Disconnect the air fuel ratio sensor connector and remove the bolt and air fuel ratio sensor bracket.

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

Torque:

43 N*m{438 kgf*cm, 32 ft.*lbf}

HINT:

Attach an engine sling device and hang the engine with a chain block.

Remove the bolt and heat insulator from the steering gear.

Remove the clamp and disconnect the steering column hole cover from the steering gear.

Remove the bolt and front suspension crossmember from the engine.

Disconnect the terminal cap.

Remove the nut and disconnect the starter wire.

Disconnect the connector.

Remove the 2 bolts and starter.

Remove the flywheel housing side cover from the cylinder block.

Remove the continuously variable transaxle assembly (RAV4_ACA30 RM00000192D01ZX.html).

for 2WD:
Remove the manual transaxle assembly (RAV4_ACA30 RM000001B3W02LX.html).

for 4WD:
Remove the manual transaxle assembly (RAV4_ACA30 RM000001B3W02WX.html).

Using SST, hold the crankshaft.

SST

09330-00021
09213-58014(91551-80840)

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

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 a union nut wrench, separate the orifice to flexible hose tube from the clutch orifice assembly.

Remove the bolt and orifice to flexible hose tube.

Using a union nut wrench, remove the clutch release cylinder to accumulator tube.

Remove the 2 bolts and clutch orifice assembly.

Using a union nut wrench, separate the clutch release bleeder sub-assembly from the clutch release cylinder to bleeder tube.

Remove the 2 bolts and clutch release bleeder sub-assembly from the manual transaxle assembly.

Remove the clutch tube boot from the manual transaxle assembly.

Remove the 3 bolts and clutch release with bearing cylinder assembly and clutch release cylinder to bleeder tube.

Using a union nut wrench, remove the clutch release cylinder to bleeder tube from the clutch release with bearing cylinder assembly.

Using SST, hold the crankshaft.

SST

09330-00021
09213-58014(91551-80840)

Remove the 8 bolts and flywheel.

Install the engine onto an engine stand with the bolts.

Remove the 2 bolts, and 2 engine hangers.

Remove the engine wire from the engine.

Remove the 3 bolts and bearing bracket.

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

Remove the bolt and radiator reservoir bracket.

Remove the 3 bolts and engine mounting insulator.

Remove the bolt and wire harness clamp bracket.

Remove the 4 bolts and engine mounting insulator.