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HOMESERVICE MANUALSTOYOTA2020RAV4 XLE, AWDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 34 (ENGINE INTAKE / EXHAUST SYSTEM (A25A-FXS) - SERVICE INFORMATION)INTAKE MANIFOLDREMOVAL [02/2019 - 08/2020]PROCEDURE
2020 Toyota RAV4 XLE, AWD

Removal [02/2019 - 08/2020]: Procedure

2020 Toyota RAV4 XLE, AWDSECTION Procedure
WARNING: This page is about a different variant/trim than selected.
  1. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to REMOVAL [02/2019 - 08/2020]

  2. REMOVE EGR VALVE ASSEMBLY 

    Refer to REMOVAL [02/2019 - 08/2020]

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

    Refer to PROCEDURE - Step 1

  4. REMOVE PURGE VALVE (PURGE VSV) 

    Refer to PROCEDURE - Step 1

  5. 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.
  6. 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.
  7. 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.
  8. 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
  9. REMOVE INTAKE MANIFOLD 
    1. w/o Stud Bolt:
      GTY943117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
  10. 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
  11. REMOVE NO. 1 ENGINE COVER 
    1. Remove the clip and No. 1 engine cover.
      GTY771528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE VACUUM HOSE 
    1. Remove the vacuum hose from the intake manifold.
      GTY754161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.