Engine Blocks Can Cause Engine Failure Leading To Engine Stall (Non-hybrid) and/or Fire Risk – 2019-2020 Toyota RAV4

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IMPORTANT UPDATE TECHNICAL INSTRUCTIONS FOR SAFETY RECALL 20TA04 CERTAIN ENGINE BLOCKS CAN CAUSE ENGINE FAILURE LEADING TO ENGINE STALL (non-hybrid) and/or FIRE RISK CERTAIN 2019 – 2020 RAV4 (2020 RAV4 HV is a separate document) Update 6/24/2020: Engine Assembly Replacement procedure is now included The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians performing this recall are required to successfully complete the most current version of the E-Learning course “Safety Recall and Service Campaign Essentials”. To ensure that all vehicles have the repair performed correctly; technicians performing this recall repair are required to currently hold at least one of the following certification levels: • Expert Technician (Engine) • Master Technician • Master Diagnostic Technician It is the dealership’s responsibility to select technicians with the above certification level or greater to perform this recall repair. Carefully review your resources, the technician skill level, and ability before assigning technicians to this repair. It is important to consider technician days off and vacation schedules to ensure there are properly trained technicians available to perform this repair at all times. 2 I. OPERATION FLOW CHART Does the Campaign website indicate that replacement of the Engine Assembly is required? Covered Campaign completed, return the vehicle to the customer Not ..Covered.. No further action required Yes Replace Engine Assembly Verify Vehicle Eligibility 1. Confirm vehicle VIN matches the RO. 2. Check Vehicle Inquiry System for Campaign eligibility. Perform Block ID No. inspection Enter the Block ID No. into the Campaign website and upload photo ..No.. II. IDENTIFICATION OF AFFECTED VEHICLES • Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Safety Recall, and that it has not already been completed prior to dealer shipment or by another dealer. • TMS warranty will not reimburse dealers for repairs completed on vehicles that are not affected or were completed by another dealer. 3 III. PREPARATION A. PARTS INSPECTION ONLY: No parts are required for the inspection of the Block ID No. Parts will only be necessary if the replacement of the Engine Assembly is required, as determined by the inspection. ENGINE ASSEMBLY REPLACEMENT: Because of the extensive list of parts and variations of the model, a website has been created to detail the required parts for each vehicle. Reference the following website for a detailed parts list for each specific VIN: https://20TA04-20LA02-safety-recall.imagespm.info/ Note: Warranty will only reimburse dealers for the part numbers listed on the website. Any other part numbers will not be accepted on the campaign claim. B. TOOLS & EQUIPMENT • Techstream • Standard Hand Tools • Torque Wrench • Engine Hoist • Engine Stand SST – These Special Service Tools required for this repair: Part Number Tool Name Quantity 00002-11100-02 Transmission Fluid Pump 1 IV. BACKGROUND Some of the subject vehicles may be equipped with an engine block that was manufactured incorrectly. This issue may cause coolant to leak internally and/or externally during normal engine operation. This can lead to engine noise, engine smoke, warning lights/malfunction indicator illumination, an audible chime sounding, and/or, in some cases, engine overheating and possible internal mechanical engine damage. If this occurs in a conventional gasoline vehicle, it is possible the vehicle could stall while driving at higher speeds without prior warning, increasing the risk of a crash. For both hybrid and conventional gasoline vehicles, the mechanical engine damage could cause engine oil to leak, which, in the presence of an ignition source, can lead to an increased risk of fire. NOTE: If the engine stalls in a hybrid vehicle, the vehicle will enter a fail safe driving mode, allowing the driver to operate the vehicle at reduced power for certain distances to maneuver the vehicle to a safe location. 4 V. COMPONENTS 5 6 7 8 9 10 11 2WD 12 AWD 13 14 (Diagram detail on next page) 15 16 (Diagram detail on next page) 17 18 (Diagram detail on next page) 19 20 21 22 23 VI. BLOCK ID No. INSPECTION for 2WD RAV4 AWD models are detailed on p. 25 1. REMOVE CENTER No. 4 ENGINE UNDER COVER a. Raise the car on a lift to gain access to the bottom of the vehicle. b. Remove the 4 screws to remove the Center No. 4 Engine Under Cover. 2. LOCATE ENGINE BLOCK ID No. a. Reference the photo below to locate the Block ID No. stamping. b. Use a clean, wet rag to wipe clean the area of the stamping. Block ID No. 24 3. TAKE A PHOTO OF THE BLOCK ID No. a. Use a digital camera to take a photo of the Block ID No. Be sure to place the camera as straight and level as possible to the surface of the stamping. 4. REVIEW PHOTO a. Zoom in on the Block ID No. in the photo to be sure all 12 characters can be clearly read. If all 12 digits are not legible, retake the photo. Note: If the Block ID No. is unreadable after properly cleaning the surface and retaking the photos, send an email to Quality Compliance: Email address: Quality_Compliance@Toyota.com Subject: Block ID Unreadable Provide the following: • Attachment: Quality photo of the Block ID No. • Dealer Code • Technician Name • VIN # • Explanation of the problem Once this email has been sent, please wait for an email response from Quality Compliance. They will provide directions for your next step. Skip to Section VIII. Determine Inspection Result on p. 29 25 VII. BLOCK ID No. INSPECTION for AWD 1. REMOVE CENTER No. 4 ENGINE UNDER COVER a. Raise the car on a lift to gain access to the bottom of the vehicle. b. Remove the 4 screws to remove the Center No. 4 Engine Under Cover below the engine oil pan. 2. LOCATE BLOCK ID No. (RAV4 AWD only) The Block ID No. location on the RAV4 AWD can be seen from below by looking between the axle support carrier and the transfer case. Note: The viewing angle is too steep to be able to read the Block ID No. It will be necessary to use an endoscope to take a photo of the Block ID No. as the transfer case prohibits access with a camera. Block ID No. 26 3. CLEAN THE BLOCK ID No. SURFACE The surface of the Block ID No. cannot be easily reached with a rag or wire brush for cleaning. It may be necessary to use a Tube Brush or Bore Brush with a long handle to reach the area. a. Use a Tube Brush or Bore Brush to scrub the surface of the Block ID No. Example: Harbor Freight Tube Brush Set (Item 61923) Hint: Bend the handle slightly to clear the upper oil pan 4. SET UP ENDOSCOPE Your dealership was provided with a Depstech 85S Endoscope for Safety Recall J0M. This same endoscope will be used for this activity. If necessary, these tools can be purchased from many online retailers such as Amazon. a. Plug the Depstech 85S Endoscope into a USB port of the Techstream. b. Select the following link to download the Smart Camera software for the Depstech NTC 85S endoscope, if needed. Smart Camera 3.1.2 download Note: The software for this Depstech NTC 85S can also be downloaded at the Depstech website: https://www.depstech.com/index.php?route=product/support c. Select the Settings tab at the bottom of the Smart Camera screen. 27 d. Verify the following settings: • Device: SMI • Video Format: MJPG 640×480 The default values on the remainder of the settings will be acceptable. e. Maximize the photo display area by selecting the Full Screen icon. 5. POSITION ENDOSCOPE It will be necessary to use the endoscope to take a photo of the Block ID No. You can view the Block ID No. by positioning the Endoscope over the top of the transfer case, as shown below. Block ID No. Insert Endoscope here 28 6. TAKE PHOTO a. Turn on the endoscope light by adjusting the thumbwheel on the cord, close to the USB plug. b. Guide the endoscope over the top of the transfer case and locate the Block ID No. c. Select the TAKE PHOTO icon to save the image. Note: Take a few different photos to be sure that one has the clarity to read all 12 digits of the Block ID No. 7. LOCATE PHOTOS a. Select the FULL SCREEN icon at the bottom of the screen b. Select the PHOTOS tab at the bottom of the Smart Camera screen. 8. Save each of the photos so they can be accessed later. Note: Photos of the Block ID No. will be required to upload into the Inspection Website in the next steps, so be sure to save the photos. 9. REVIEW PHOTO a. Review the photos of the Block ID. No.’s to determine which photo clearly displays the 12 digits. Note: If the Block ID No. is unreadable after properly cleaning the surface and retaking the photos, send an email to Quality Compliance: Email address: Quality_Compliance@Toyota.com Subject: Block ID Unreadable Provide the following: • Attachment: Quality photo of the Block ID No. • Dealer Code • Technician Name • VIN # • Explanation of the problem Once this email has been sent, please wait for an email response from Quality Compliance. They will provide directions for your next step. 29 VIII. DETERMINE INSPECTION RESULT 1. OPEN INSPECTION WEBSITE a. Open the 19TA04 Inspection Website by selecting the following link: https://20TA04-20LA02-safety-recall.imagespm.info/ b. Enter your dealer code in the User ID field. c. Enter xxxxx for the Password. It will then prompt you to change the password. You can enter the same (5 x’s) again, or create your own password. If you do change the password, be sure to advise other technicians of the updated password. Note: Selecting the “Forgot Password” link will reset the password to the default password: xxxxx d. Enter the vehicles VIN. It is critical that the VIN be entered accurately. 2. ENTER BLOCK ID No. a. Enter the top row of the Block ID No. (6 digits) when prompted. NOTE: All 6 digits are NUMBERS. b. Enter the bottom row of the Block ID No. (6 digits) when prompted. NOTE: The first digit is a LETTER, the remaining digits are NUMBERS. 5. UPLOAD PHOTO a. The website will require a photo of the Block ID No. to be uploaded. Be sure that all 12 digits of the Block ID No. are legible in the photo. 30 3. REVIEW INSPECTION RESULTS a. Review the results provided by the website after inputting the Block ID No. Is replacement of the Engine Assembly necessary? Proceed to Section VIII. ENGINE ASSEMBLY REPLACMENT on p. 31 Proceed to Section IX. REASSEMBLE VEHICLE on p. 30 ..YES.. ..No.. IX. REASSEMBLE VEHICLE (Engine Replacement NOT Necessary) 1. INSTALL CENTER No. 4 ENGINE UNDER COVER a. Install the center No. 4 engine under cover with the 4 screws. The Campaign is now complete. Return the vehicle to the customer. 31 X. ENGINE ASSEMBLY REPLACEMENT Engine Assembly Replacement is necessary ONLY if directed by the inspection website. DO NOT perform this procedure unless directed. 1. REMOVE ENGINE & TRANSMISSION FROM VEHICLE a. Follow the Repair Manual Process to remove the engine from the vehicle. 2019: A25A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL; 2019 MY RAV4 (RM100000001EC20) 2020: A25A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL; 2020 MY RAV4 (RM100000001LRD9) 2. UPDATE ENGINE SERIAL NUMBER a. Send an email to quality_compliance@toyota.com with the following information: • Subject: 20TA04 Engine Serial Number Update • Vehicle Identification Number (VIN) • Serial Number from the ORIGINAL engine • Serial Number from the NEW engine Engine Serial Number location Example: G052976A25A 3. REMOVE ENGINE MAIN HARNESS a. Remove the engine main harness from the original engine. 32 4. TRANSFER DRIVE SHAFT BEARING BRACKET a. Remove the 3 bolts and drive shaft bearing bracket from the original engine. b. Install the drive shaft bearing bracket and 3 bolts onto the NEW engine. Torque: 47 lbf.ft {63.7 N∙m, 650 kgf∙cm} 5. TRANSFER COMPRESSOR ASSEMBLY (with stud bolts) a. Remove the 2 bolts and 2 nuts from the original engine. b. Using a E8 “TORX” wrench, remove the 2 stud bolts and compressor assembly. c. Install the 2 stud bolts onto the NEW engine. Torque: 7 lbf.ft {10 N∙m, 102 kgf∙cm} d. Install the compressor assembly onto the NEW engine with the 2 bolts and 2 nuts. Torque in the sequence shown. Torque: 18 lbf.ft {24.5 N∙m, 250 kgf∙cm} 33 6. TRANSFER COMPRESSOR ASSEMBLY (bolts only) a. Remove the 4 bolts and compressor assembly from the original engine. b. Install the compressor assembly and 4 bolts onto the NEW engine. Torque in the sequence shown. Torque: 18 lbf.ft {24.5 N∙m, 250 kgf∙cm} 7. TRANSFER GENERATOR ASSEMBLY a. Remove the 2 nuts and bolt from the original engine. b. Using a E8 “TORX” wrench, remove the 2 studs. c. Install the 2 studs onto the NEW engine. Torque: 87 lbf.in {9.8 N∙m, 100 kgf∙cm} d. Install the original generator onto the NEW engine. e. Install the 2 nuts and bolt. Torque: 18 lbf.ft {25 N∙m, 255 kgf∙cm} 8. TRANSFER NO. 2 ENGINE COVER a. Remove the 2 bolts and cover b. Install the cover and 2 bolts onto the NEW engine. Torque: 7 lbf.ft {10 N∙m, 102 kgf∙cm} 9. TRANSFER NO. 2 WATER BY-PASS PIPE a. Remove the bracket bolt from the original engine. b. Slide the clamp and remove the hose. c. Install the hose and clamp onto the NEW engine. d. Install the bracket bolt. Torque: 14 lbf.ft {19 N∙m, 194 kgf∙cm} 34 10. TRANSFER FLOW SHUTTING VALVE a. Remove the bolt from the original engine. b. Remove the 2 bolts and the water hose bracket. c. Remove the clamp and hose from the original engine. d. Install the hose onto the water outlet of the NEW engine. e. Install the bracket onto the NEW engine with the 2 bolts. Torque: 10 lbf.ft {13 N∙m, 133 kgf∙cm} f. Install the valve to the bracket. Torque: 14 lbf.ft {19 N∙m, 194 kgf∙cm} 11. TRANSFER EXHAUST MANIFOLD a. Remove the 5 bolts from the heat insulator. b. Remove the manifold stay on the bottom. c. Using a 12mm deep socket, remove the 7 nuts and separate the exhaust manifold. Note: Discard the 7-exhaust manifold nut’s as they will not be reused. d. Install a NEW exhaust manifold gasket onto the NEW engine. 35 e. Install the exhaust manifold onto the NEW engine. f. Temporarily install the 7 NEW nuts onto the studs. g. Using a 12mm deep socket, torque the 7 nuts in the sequence shown. Torque: 19 lbf.ft {26 N∙m, 265 kgf∙cm} h. Install the manifold stay and the nut and bolt. i. Torque the nut and bolt in the sequence shown Torque: 32 lbf.ft {43 N∙m, 438 kgf∙cm} j. Install the heat insulator with the 5 bolts. Torque: 7 lbf.ft {10 N∙m, 102 kgf∙cm} 12. TRANSFER PURGE VALVE a. Unbolt the purge valve from the mounting bracket on the original engine. b. Disconnect the hoses at the other end (opposite the purge valve) c. Install the purge valve on the NEW engine, attaching the hoses properly. Install the bolt to the mounting bracket. Torque: 7 lbf.ft {10 N∙m, 102 kgf∙cm} 13. TRANSFER FUEL TUBE a. Disconnect the fuel tube at the high-pressure fuel pump of the original engine. 36 b. Disconnect the fuel tube at the low-pressure fuel rail of the original engine. c. Install the fuel tube to both the low-pressure fuel rail and the high-pressure pump of the NEW engine. 14. TRANSFER No. 1 VACUUM PUMP HOSE a. Pinch the retainer of the No. 1 vacuum hose connector, then pull the connector off the vacuum pump assembly. b. Install the No. 1 vacuum pump hose onto the NEW engine. 15. TRANSFER No. 5 WATER BYPASS HOSE a. Remove the No. 5 water bypass hose from the original engine. b. Install the No. 5 water bypass hose onto the NEW engine. 16. TRANSFER FUEL DELIVERY GUARD a. Remove the bolt and fuel delivery guard from the original engine. b. Install the fuel delivery guard and bolt onto the NEW engine. Torque: 30 lbf.ft {40 N∙m, 408 kgf∙cm} 37 17. INSTALL ENGINE MAIN HARNESS a. Install the engine main harness onto the NEW engine. 18. REMOVE TRANSMISSION ASSEMBLY FROM ORIGINAL ENGINE a. Follow the Repair Manual Process to separate the engine and transmission. 2019 2WD: UB80E (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: REMOVAL; 2019 MY RAV4 (RM100000001E6JQ) 2019 AWD: UB80F (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: REMOVAL; 2019 MY RAV4 (RM100000001E6MZ) 2020 2WD: UB80E (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: REMOVAL; 2020 MY RAV4 (RM100000001K1C6) 2020 AWD: UB80F (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: REMOVAL; 2020 MY RAV4 (RM100000001LU35) 19. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY TO NEW ENGINE a. Follow the Repair Manual Process to join the engine and transmission together 2019 2WD: UB80E (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION; 2019 MY RAV4 (RM100000001E6JP) 2019 AWD: UB80F (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION; 2019 – 2020 MY RAV4 (RM100000001E6MY) 2020 2WD: UB80E (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION; 2020 MY RAV4 (RM100000001K1C9) 2020 AWD: UB80F (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION; 2019 – 2020 MY RAV4 (RM100000001E6MY) 20. INSTALL NEW ENGINE & TRANSMISSION INTO VEHICLE a. Follow the Repair Manual Process to install the engine into the vehicle. 2019 & 2020: A25A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION; 2019 – 2020 MY RAV4 (RM100000001EC22) ◄ VERIFY REPAIR QUALITY ► • Verify all DTC’s have been cleared. • Verify the air cleaner cap and hose are properly installed. • Verify there are no oil or coolant leaks. • Test drive the vehicle to confirm normal operation. If you have any questions regarding this update, please contact your regional representative. 38 19 19 = 2019 20 = 2020 21 = 2021 22 = 2022 23 = 2023 Etc… Year Campaign is Launched 19TA01 T T = Toyota L = Lexus Vehicle Make A A = Safety Recall Remedy B = Safety Recall Interim C = Special Service Campaign D = Limited Service Campaign E = Customer Support Program F = Emissions Recall (May use other characters in unique cases) Field Action Category and Phase 01 01 = 1st Field Action of the year 02 = 2nd Field Action of the year 03 = 3rd Field Action of the year (The sequence is unique for each Field Action category) (May use other characters in unique cases) Field Action Sequence Examples: 19TA01 = Launched in 2019, Toyota, Safety Recall Remedy Phase, 1st Safety Recall Launched in 2019 20TC02 = Launched in 2020, Special Service Campaign, 2nd Special Service Campaign Launched in 2020 21TE05 = Launched in 2021, Customer Support Program, 5th Customer Support Program Launched in 2021 XI. APPENDIX A. PARTS DISPOSAL As required by Federal Regulations, please make sure all recalled parts (original parts) removed from the vehicle are disposed of in a manner in which they will not be reused, unless requested for parts recovery return. B. CAMPAIGN DESIGNATION DECORDER

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