1996 - 2000 Toyota Rav4 DIY Remove Throttle Body, IAC Valve, EGR Valve, EGR Pipe, with Bench Tests 

Update: torque valve for the EGR pipe union nut (46:50) is 43 ft-lbs. Torque values for the four manifold stay/bracket (48:54) are 31 ft-lbs for the 14mm, and 15 ft-lbs for the 12mm nut and bolts. Video links for the EGR Diagnostics Video and the VSV Video are below the Timestamps: 00:01:27 Location of EGR Valve and notes about removal 00:01:23 Remove Air Box and Air Intake Hose 00:03:00 Throttle body -- closer look 00:03:13 TPS (Throttle Position Sensor) location 00:03:25 IAC (Idle Air Control Valve) location 00:03:45 Disconnect electrical for TPS and IAC Valve 00:04:15 Remove Throttle Body vacuum hoses 00:04:48 Disconnect throttle link and kickdown cables 00:05:17 Remove three Throttle Body mounting bolts (12mm) 00:06:00 Disconnect Coolant Hoses and Vacuum Hose from Throttle Body 00:08:06 Remove Throttle Body 00:08:42 Throttle Body on Bench: various components on the Throttle Body 00:10:08 IAC Valve and TPS screws are JIS (Japanese Industrial Standard) screws 00:11:35 Remove four JIS screws for IAC Valve 00:13:15 Removing stripped JIS screw for IAC Valve 00:15:23 Remove IAC Valve from Throttle Body 00:16:14 More JIS screws on IAC Valve 00:16:35 Clean IAC Valve 00:17:55 Removing screws for pintle access on IAC Valve 00:21:41 Bench test IAC Valve 00:24:38 Clean Throttle Body 00:25:53 Install IAC Valve back to Throttle Body (gasket is Felpro 61085) Skip ahead to 52:30 for Throttle Body re-install if you aren't removing the EGR valve. 00:27:45 Remove EGR Valve 00:30:37 Clean EGR Valve 00:32:05 Gaskets for EGR Valve (Toyota 25627-74011 and 25628-74010) 00:32:17 Bench Test EGR Valve Skip ahead to 50:00 for EGR valve re-install if you aren't removing the EGR pipe. 00:38:31 Remove Components for EGR Pipe access 00:39:03 Remove Manifold Stay parts 00:42:49 Notes about differences with '96 and '97 Rav4s (distributors) 00:43:51 Open the nut for the EGR pipe 00:45:00 Remove EGR pipe 00:45:22 Clean EGR pipe 00:46:02 Reinstall EGR pipe (torque is 43 ft-lbs) 00:47:09 Reinstall Manifold Stay parts (torque for the 14mm bolt is 31 ft-lbs; torque is 15 ft-lbs for the three 12mm's) 00:49:58 Reinstall EGR Valve (torque for 12mm nuts is 108 inch-lbs/9 ft-lbs, 10mm bolts are 87 inch-lbs) 00:51:57 Connect hoses for EGR Valve (exhaust on bottom and vacuum on top) 00:52:26 Reinstall Throttle Body 00:52:36 Connect coolant and vacuum lines to Throttle Body 00:55:30 Throttle Body gasket (Felpro 61083) 00:56:30 Install three bolts to mount Throttle Body (12mm, torque is 168 inch-lbs/14 ft-lbs) 00:57:12 Connect throttle link and kickdown cables 00:57:37 Connect vacuum hoses 00:58:04 Connect electrical for TPS and IAC Valve 01:00:27 Install air hose and air box 01:02:47 Last check on re-installed parts 01:03:58 Conclusion, recommended to disconnect battery to re-learn idle. Full EGR Diagnostics, Engine Testing, and Bench Testing video for EGR Valve, Vacuum Modulator, and VSV: ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-pdpnk2f7gnc.html Full bolt-by-bolt for removing, testing and replacing the VSV: ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-1Z-sy6z14D8.html Thanks for watching! I hope this video was helpful for you. Good luck with your repair!

You, ma'am, are the gold standard to which any instructional video creator should aspire towards. I appreciate the clarity and detail that you put into this.

This is the absolute BEST video on car repair/diagnostics ever..... You give clear and concise instructions with clear pics.... You give a great explanation of how each part works . This is just the most thorough video I've ever come across . I do my own repairs and have watched countless videos , so I know that puts this video at the top of the list of 100's if not 1000's of videos I've watched.... And I might be out of place , but it sounds like its a female making the video. If so , you're awesome.....

I have a 1998 Toyota RAV4 2.0 L with A/T that I've owned for a year. A few months ago she suddenly wouldn't idle! My mechanic replaces the IAC. Videos like this make it possible for DIYers to complete a job like this and save $$$ for labor and parts.

Exceptional tutorial! Your clarity and thorough descriptions are among the best I’ve ever seen. I have been watching DIY auto videos for years and you give the very best a new benchmark! Your soothing voice, inclusion of setback challenges, and pause video text clarifications have inspired me to up my own teaching methods. Thank you for this generous gift!!😊

Those IAC valve screws are hard to break free. I was in my friend's driveway and he didn't have many tools... I couldn't get them to budge with the Phillips drivers that he had... they didn't fit well and I was worried... that it wouldn't go well. So, I chucked his Phillips drivers and grabbed a slotted driver (which hardly fit). I knew it was a gamble. The slotted/flat bit driver didn't give me much confidence. I pressed on that rascal with all of the force I could exert and then applied torque to the screw. CLICK! One came free!! I think it only had two screws (the other two screw cavities were vacant). I removed the IAC and inspected. I didn't notice anything "wrong " with it. But it seemed a little sloppy: it wasn't a solid in the radial plane. Upon further troubleshooting(I connected the wiring/plug and turned the key on an off. I noticed that it made a funny noise ?... I took a break and researched the problem. I watched yir video and stepped back on the mat. After 15 minutes I was done. It was a old IAC. I replaced it and the problem went away.

Most well-maintained Rav4 to ever exist.

This is the best step by step video I've seen on RU-vid it has helped me so much. I have a 99 rav4 with a P0401 code that keeps coming back.

Thank you so much for these exceptional DIY vids!!! Just cleaned the EGR valve on my '97 5spd. Instead of two bolts holding it to the pipe on mine it's a 24mm nut. I used a 24mm crowfoot on a ratchet extension to take it off. To get to the other end of the pipe I removed the distributor. The crowfoot wrench made this job very easy for me (inexperienced)

Another excellent video from this channel. Rather than just following along, with this video you'll actually understand what you're doing, and what difficulties real people might run into. Great camera work and editing too. Thank you again L35!

I have watched too many videos on EGR removal and your video finally showed me the way to properly take it off! Thanks!

best instructional videos yet. i love how you provide part numbers and info on the screws, i would have never known!

I can’t believe that I finished the whole video! Such a great step by step video. I have a highlander but still enjoyed the video. 👍

I am so impressed by this video that I had to leave a comment before I've finished watching it. Thank you for your instruction and time. I have this exact car except it's a 5 speed. What would be different in removing the EGR Valve if anything?

Seeing that the lower EGR pipe comes out pretty easily surprised me. Great video, L35. Many thanks.

You're very thorough and easy to follow. Excellent video 🇨🇦👍

OUTSTANDING process instruction and video production as always ... Bravo !

Subscribed b4 even halfway and pulled up harbor freight so I can put tools in my fave list just to have what she'll (98 RAV4 3sfe) need for whenever. Just got her a few mths ago replacing my 03 1azfe so I'm learning. I think I'll just delete other videos because this right here is pure gold and I'm very impressed with the details, camera angles and your voice is soothing. Tysm for the video, I'll probably be binging your other vids just to see what I can see 😅🤷🏾‍♀️.

Thank you L35!!! Very generous of you to put so much time into helping others :)

One more state of the art diagnose and repair EGR system components - - Thank you so much Ms. L35 in Colorado

Apparently my throttle body needed to be cleaned? Not really that gunky, but IDK, I'm not a mechanic. This video helped me to do it, though I didn't take it off the engine. Thanks.

This is fantastic!! So clear and concise. And actually helpful. And well filmed. And....wow. bravo!

Followed your guide to a T. Got my 97 with 265000 miles singing like bird... likea boyud!

Awesome video ! Hope you make a video on how to replace the throttle cable. Mine keeps loosing up and have to tighten up every three days 😪

Super nice video. I'll give you the best comment I can. If I had a shop, I'd hire you in a NY minute! My 2001 Camry has the dreaded P0401. Trips the code, and also P0442 (small EVAP leak) when I go up hill. My guess is a vacuum leak starving both systems. I have health problems and don't do my own work. Hard to find experienced, thorough people like you here in upstate NY.

Gotta love these first gen ravs!

These are great RAV4 videos!! I just broke the bottom 10mm bolt between the EGR pipe and the EGR trying to remove it (lots of penetrating fluid). 2000 5S-FE engine, looks just like your RAV4 engine. My background is that I'm a DIY person, I've been working on my cars and house doing more complicated things as time goes on. I have the 2 nuts and the other bolt out of the EGR. It looks like I could take a sawzall and cut off the top of the EGR valve, drill down through the lower EGR hole where the rest of the broken bolt still is (now that the round top of the valve is gone), and get the rest of the EGR valve off that way. It doesn't look like the holes where the EGR pipe mount to the EGR valve are threaded, so if I go slightly off as I'm drilling, this doesn't seem like it would turn out bad (just screw on new 10mm bolts through my new gasket), etc. Does this seem like a good approach, or is there an easier or better way?

Good system to teach a subject With simple words although subject is difficult to common man Thanks madam

L35 my friend Elle_RAV4 sent me your video. Congratulations, wonderfully thorough. Seems you love your GEN-1 RAV4 as much as we do ours. Amazing how easily that EGR "pipe" was removed. This is a GODSEND! THANK YOU!

Your videos are awesome , please do more !

Good Morning Thank you , detailed and informative video. Will be attempting above procedure on 96 RAV4, feel confident about this maintenance , RAV4 will perform good as new. I pray many people view your video and give thumps up and subscribe. We give this video a 10 out of 10 rating.

Dude, that's a video and a half. Nice job.

Congrats for making the best video for this gen of the Rav4 🙏🏻, it is really helpful for me, but I'm curious, why did you use Felpro gaskets instead of the OEM? 👀

If there is enough "tool clearance" to apply Vice-Grips to the periphery of the screw... only a few degrees of rotation may break the fastener free. From that point, it's done. Usually.

Excellent Video - very clear and easy to follow - thank you

Congratulations, impressive video that has helped me to disassemble the EGR of my Rav4, thank you very much for sharing, greetings.

I love your videos. My Rav thanks you lol. It's been through a lot. I just did motor mounts, and I still have a slight shake while in park. I'm going to do a full clean on the TB.

Brilliant suff. super clear. very helpful!!

I like your video. I learned so much from your video. You explained very well the functions of the throttle body and it's egr.

This is an incredibly detailed and well though out video. Great work.

Спасибо, с клапана егр с низу должен пропускать воздух со штока пропускает в доль штока клапана с впускного коллектора? Проверели дымом оттуда идёт(

53:10 I just realized I hooked the hoses wrong so I'm gonna remember to watch this again to follow the short and long hoses

Excellent -- I LOVE YOUR VIDEOS!! Thank you!!! I can watch over and over. Question the torque wrench what brand and size 3/8 or 1/4?

Hi L35 THANK YOU soo much for the time and detail representation in troubleshooting and resolving this nightmare code most professional mechanics can't figured it out. One question though, could you please share the part number or brand of hand pump so I can order it at a auto parts or Amazon please.

awesome video! Well done!!! Will be cleanin my throttle body and new gasket as well as a new IAC. this video will help a lot

I wish that was my Rav4 LOL You're Amazing ❤️

Excelente video, ¿ tendrás algo sobre el cambio de aceite a la caja automática de la Toyota rav4 1998 ?

Your videos are awesome thanks

Very well done instructional!!

You are an excellent mechanic!

Great educational instruction, Thanks! Why is does the IAC use coolant input and output ports? I just replaced one of the hoses and it was a very tough job on the engine side of the hose. My car is a 96 Rav4 2.0 liter. Still runs great at 214 k. Thanks.

I subscribed before I was even done with the video 😂. Very satisfyingly great video. Good job

If possible, please mention at the beginning of your videos the other Toyota years/makes/models with which the RAV 4 work is compatible. I have a 1997 Camry 2.2 L 4 cyl. I am guessing its the same set up. Great videos ! Thanks for your patient hard work.

Thank you so much I have a 98 and need to do this and replace my cv axle I also live in Colorado

your videos should be the standard for people making car repair videos! I need help. Where does the vacuum hose terminate on the opposite end from the IAC?

I’ve been struggling with the jis screws on the IAC valve. They’re so tight and the person who owned it before me already cammed out the screws so I’m left with nothing left to do but to extract them I’m guessing. Just need to get the new screws before I mutilate the other ones lol. Damn thing is stuck open and idling high.

Respect 👍

Which manual/book are you using?.Could you kindly share a link to download the soft copy

My god...... You are the best😊😊😊

Hi, I was wondering if you could tell me where that vacuum hose comes from that hooks into the bottom of the IAC valve that vacuum hose is missing off of mine I cannot find the other end anywhere

How can i fix the failing of plug smoke color results from my rav4 gx toyota 1996 model 3s engine

Would you have a link on a replacement idle adjustment screw? Mine is stripped. Any chance you would also know what the idle rpms should be once I put a new screw in there?

Does this RAV4 gen have a mass air flow sensor ?

Super excellent tutorial video 👍👍

Hello, thanks for your video. One question, I have a 2008 Toyota Corolla with 230,000 km of manual gearbox. The fault is that when you turn it on it starts with 1300 rpm and as it warms up it goes up to 2000, that is, it does it the other way around since I understand it should go down to about 900 rpm. and when I'm hot I go out and when I make the gear changes I see that the rpm oscillates between 2000 and 1000 rpm and when I continue the march the minimum is 2000 rpm. If I leave it running stopped the car stays at 2000 rpm. I clarify that with a scanner it does not give an error. Well, we took out the carburetor, total cleaning including the filter's MAF sensor, I clarify that you can't take out the IAC valve to clean it, but the carburetor body was immersed in non-abrasive remover liquids and a lot of dirt came out. We measured TPS and IAC with a multimeter, simulated with power and everything was fine. We checked the pipes that had never been touched and were untouchable. We put everything together and it starts doing the same fault. Then I disconnected the EGR vacuum valve and there the rpm's dropped a little but after five seconds it accelerates and when connected it returns to 2000 rpm. Could it be a faulty EGR vacuum valve?

Thanks!

What a great video. Camera work and and attention to all the details is excellent. How are you holding the camera? Do you have a video about your setup? Thanks!

Great video thank you very much !!!

I saw another video saying that I can simply clean the IAC for a rough idle. Is this correct? Why would a person do all of this other stuff? What would you recommend doing for a 97 rav that wasn't maintained well the past 6 yrs(because of my bad experience with mechanics shops). Has about 148000miles on it. I plan to do all fluid flushes and a tune up. It jumps when put into reverse(I plan to check with amco to see if the transmission is still under warranty) and the idle goes up and down, occasionally shakes, there is a screech when it first starts and a small oil leak from somewhere that has gotten a bit bigger over the past 6 yrs. Thank you so much for your awesome videos!

cheers for this video, absolutely the most in depth for this subject I have been able to find🎉 some day i hope my rav is as well maintained 😂

I usually take a small flat chisel of screwdriver and just hammer it till it becomes a bit loose not recommended but may work if you dont have a grinder lol

I got the same brush gaurd

Where can I buy the vacuum line for the idle air control valve? Having trouble finding it and need to replace mine.

I have injector cleaner, how can I use it to idle air control or carburator without release the parts?

Is the vacuum hose that goes under the throttle body a special hose, or can I just buy hose at a local auto parts store? Mine is starting to split and I am wanting to replace it.

Thanks Micheal

Great video.

My vacuum modulator pipe is completely blocked. Any ideas for clearing it?

Hi, What's the P/N of the rear cam seal or plug?

What was that hose in your hand at 2:45? Looks like my folks' RAV4 had burst at the small to big section.

Great video thank you very much and I would like to ask you about fixing the IAC valve and What is the adhesive material that is placed under the sensor? Also, in the event that the two screws that you spoke about and warned against opening them were opened I hope you answer me Thank you very much Sorry, I can't speak English well

Question on the Throttle valve please.. When you apply vacuum to the valve, does it hold Vacuum?

I seem to have a vacuum line right under the Throttle position sensor, that feels attached to the the throttle body, on my 2000 rav 4. Do you know what that is for, and why its different from the rav in your video?

Would this help if my car is sucking on gas?

So can the idle rpms be changed by that screw in throttle valve?

I can not find the video L35, but I'm almost positive I watched one of your videos where you recommended using only Denso PK20TR11 double platinum spark plugs for the 2000 RAV 4, instead of copper or iridium. The plugs I pulled out of the RAV I am working on are Denso Iridium. Not the right plugs?? Thanks.

Que buenas 👍

Hi, great video. What has my Rav 4 got to do with idling? It starts ok, only it doesn't idle unless I keep it accelerated. I changed the throttle and it does. Thanks.

What tools would you suggest I get to make working on the RAV4 easier ie obstruction wrenches jic screw driver and hose pipe remover pliers.

What and how are you getting the codes coz here in Australia on that model RAV4 gen 1 there is no obd2 port just the diag port in the engine bay on top of the alternator

Hi L35, can you tell me please where is the air hose from the IAC valve plugged, I mean that the hose is plugged into the IAC valve but I don't know where to put the other side of the hose, right now is unplugged and when the engine is started it seems to suck air, it will be so helpful for me, thanks 😀

L35, what size JIS bit is needed for the IACV screws? Thank you in advance. :)

Outstanding explanation, i have learned many things. My car is camry 98 model 2.2 automatic 216000 miles running. Problem with my car is it stays 1000rpm at neutral when i put on D then stays at rpm 800, if i turn on the AC then 500 and car starts shaking, i cleaned throttle body only but not idle valve or egr. Problem not solved Computer error code comes only P0401. Should i clean idle valve? I found my idle valve has only coolant 2 hoses no other gas pipe ur one is showing 3 hoses, please suggest me what to do. Thanks

Hi, do you still re me 😁😁😁 Question... What is, instead of applying suction on the upper metal protrusion on the top of EGR piece or hosing, what if I put pressure into it, is it OK if the air managed to scape from the rims of the disc?? By the way I tested the pintel hiding when applying suction on the same upper port or tube, the pintel was holding for 5 minutes.... But I wonder if pushing air in the same port is supposed to leak some where around the rim of the EGR top??? I wish you are not busy. 🤔🤔🤔

My 97 RAV4 has just started to occasionally stall at red lights, or not want to take a whole lot of throttle at acceleration out of a red light. From what I’ve read on forums, it sounds like a have a dirty IAC valve and throttle body and just need to clean it out. Do you think that’s what the issue is?

Traduci en español traducir en español latino me da igual

Those JIS screw drivers are pretty expensive!

Thats a pozidrive bit not phillips

13:09 Lol

You great, just use WD40 next time. Then that screw will come out in a second.