Toyota RAV4 manuals

Toyota RAV4 Service Manual: Installation

  1. Install cylinder head gasket

Toyota RAV4. Install cylinder head gasket


  1. Place a new gasket on the cylinder block surface with the lot no. Stamp facing upward.

Notice:

  1. Install cylinder head sub-assembly

  1. Place the cylinder head on the head gasket.

Notice:

Place the cylinder head gently in order to avoid damaging the gasket.

  1. Install the cylinder head bolts.

Notice:

The cylinder head bolts are tightened in 2 successive steps.

  1. Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.
  2. Using several steps, uniformly install and tighten the 10 cylinder head set bolts and plate washers with a 10 mm bi-hexagon wrench in the order shown in the illustration.

    Torque: 70 n*m (714 kgf*cm, 52 ft.*Lbf)

Toyota RAV4. Install cylinder head sub-assembly


  1. Mark the front of the cylinder head bolts with paint.
  2. Retighten the cylinder head bolts by 90 as shown in the illustration.
  3. Check that the paint mark is now at a 90 angle to the front.

Toyota RAV4. Install cylinder head sub-assembly


  1. Install camshaft timing gear assembly

Toyota RAV4. Install camshaft timing gear assembly


  1. Put the camshaft timing gear and camshaft together with the straight pin and key groove misaligned, as shown in the illustration.
  2. Turn the camshaft timing gear as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.

Notice:

Be sure not to turn the camshaft timing gear to the retard angle side (the right angle).

  1. Check that there is no clearance between the gear fringe and camshaft.
  2. Tighten the flange bolt with the camshaft timing gear fixed in place.

Torque: 54 n*m (551 kgf*cm, 40 ft.*Lbf)

  1. Check that the camshaft timing gear can move to the retard angle side (the right direction) and is locked in the most retarded position.
  1. Install no. 2 Camshaft timing sprocket

Toyota RAV4. Install no. 2 Camshaft timing sprocket


  1. Clamp the camshaft in a vise, then install the camshaft timing sprocket with the bolt.

    Torque: 54 n*m (551 kgf*cm, 40 ft.*Lbf)

Notice:

Do not damage the camshaft.

  1. Install camshaft

Toyota RAV4. Install camshaft


  1. Apply a light coat of engine oil to the journal portion of the camshaft.
  2. Place the 2 camshafts on the cylinder head with the no. 1 Cam lobes facing the directions shown in the illustration.
  3. Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head.
  4. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

Toyota RAV4. Install camshaft


Toyota RAV4. Install camshaft


  1. Using several steps, uniformly tighten the 20 bearing cap bolts in the sequence shown in the illustration.

Torque: 29.5 N*m (301 kgf*cm, 22 ft.*Lbf) for no.

1 And no. 2 Bearing cap

9.0 N*m (92 kgf*cm, 80 in.*Lbf) for no. 3 Bearing cap

Notice:

Install the camshaft with the timing mark of the camshaft timing gear on top.

  1. Install no. 1 Chain vibration damper (see page em-33)

  2. Install chain sub-assembly (see page em-33)

  3. Install chain tensioner slipper (see page em-34)

  4. Install timing chain guide (see page em-34)

  5. Install no. 1 Crankshaft position sensor plate (see page em-35)

  6. Install timing chain cover sub-assembly (see page em-35)

  7. Install no. 1 Chain tensioner assembly (see page em-37)

  8. Install v-ribbed belt tensioner assembly (see page em-38)

  9. Install engine mounting bracket rh (see page em-38)

  10. Install crankshaft pulley (see page em-38)

  11. Install oil pan sub-assembly (see page em-39)

  12. Install crankshaft position sensor (see page es-402)

  13. Install cylinder head cover sub-assembly (see page em-40)

  14. Install spark plug (see page em-16)

  15. Install ignition coil assembly (see page ig-9)

  16. Install idler pulley (see page em-41)

  17. Install engine mounting insulator rh (see page em-41)

  18. Install radiator reservoir (see page em-112)

  19. Install generator assembly (see page ch-15)

  20. Install fan and generator v belt (see page em-7)

  21. Install front suspension member reinforcement rh (see page em-7)

  22. Connect engine wire

Toyota RAV4. Connect engine wire


  1. Connect the ground cable with the bolt.

    Torque: 8.4 N*m (86 kgf*cm, 74 in.*Lbf)

  2. Connect the camshaft position sensor connector.
  3. Connect the engine coolant temperature sensor connector.
  4. Connect the engine oil pressure switch connector.
  5. Connect the radio setting condenser connector.
  6. Connect the heater water inlet hose.
  1. Connect no. 1 Radiator hose

Toyota RAV4. Connect no. 1 Radiator hose


  1. Connect the hose to the cylinder head.
  1. Install camshaft timing oil control valve assembly (see page es-396)

  2. Install exhaust manifold converter subassembly

  1. Install a new gasket onto the cylinder head.
  2. Temporarily tighten the exhaust manifold converter with the 5 nuts.
  3. Tighten the 5 nuts in the sequence shown in the illustration.

Toyota RAV4. Install exhaust manifold converter subassembly


Torque: 37 n*m (377 kgf*cm, 27 ft.*Lbf)

  1. Connect the air-fuel ratio sensor connector.

Toyota RAV4. Install exhaust manifold converter subassembly


  1. Install no. 1 Exhaust manifold heat insulator

Toyota RAV4. Install no. 1 Exhaust manifold heat insulator


  1. Install the exhaust manifold heat insulator with the 4 bolts.

Torque: 12 n*m (122 kgf*cm, 9 ft.*Lbf)

  1. Install no. 2 Manifold stay

Toyota RAV4. Install no. 2 Manifold stay


  1. Install the stay with the bolt and nut.

Torque: 44 n*m (449 kgf*cm, 32 ft.*Lbf)

  1. Install manifold stay

  1. Install the stay with the bolt and nut.

Torque: 44 n*m (449 kgf*cm, 32 ft.*Lbf)

  1. Install front exhaust pipe (see page ex-4)

  2. Install oil dipstick guide

Toyota RAV4. Install oil dipstick guide


  1. Apply a light coat of engine oil to a new o-ring and install it onto the guide.
  2. Install the guide with the bolt.

Torque: 9.0 N*m (92 kgf*cm, 80 in.*Lbf)

Toyota RAV4. Install oil dipstick guide


  1. Install oil dipstick

  2. Install intake manifold insulator (see page es-421)

  3. Install intake manifold (see page es-421)

  4. Install fuel delivery pipe sub-assembly (see page fu-13)

  5. Install throttle body (see page es-413)

  6. Install air cleaner cap (see page es-413)

  7. Add engine oil (see page lu-4)

  8. Connect cable to negative battery terminal

  9. Check for fuel leaks

  10. Add engine coolant (see page co-6)

  11. Check for engine coolant leaks

  1. Check for engine coolant leaks (see page co-1).
  2. Check for engine oil leaks

  3. Check for exhaust gas leaks

  4. Inspect ignition timing (see page em-1)

  5. Inspect engine idling speed (see page em-2)

  6. Inspect compression (see page em-3)

  7. Inspect co/hc (see page em-4)

  8. Install no. 1 Engine cover (see page em-43)

  9. Install front fender apron rh

  10. Install no. 1 Engine under cover

  11. Install front wheel rh

  12. Install radiator support opening cover

Reassembly
Hint: Thoroughly clean all parts to be assembled. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. Replace oil seals with new ones. Install val ...

Repair
Repair valve seats If the seating is too high on the valve face, use 30 and 45 cutters to correct the seat. If the seating is too low on the valve face, use 75 and 45 cutters to ...

Other materials:

Installation
Hint: A bolt without a torque specification is shown in the standard bolt chart (see page ss-2). Install front seat inner belt assembly (for power seat) Install the front seat inner belt assembly with the nut. Torque: 42 n*m (428 kgf*cm, 31 ft.*Lbf) Notice: Do not overlap the ...

Fuel information
You must only use unleaded gasoline in your vehicle. Select octane rating 87 (research octane number 91) or higher. Use of unleaded gasoline with an octane rating lower than 87 may result in engine knocking. Persistent knocking can lead to engine damage. At minimum, the gasoline you use sho ...

Throttle actuator control system
Description The throttle actuator is operated by the ecm, and opens and closes the throttle valve using gears. The opening angle of the throttle valve is detected by the throttle position (tp) sensor, which is mounted on the throttle body. The tp sensor provides feedback to the ecm in ord ...

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