Toyota RAV4 Service Manual: 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.

1. Install valve stem oil seal

1. Using sst, push in a new oil seal.

Sst 09201-41020

Hint:

The intake valve oil seal is gray and the exhaust valve oil seal is black.

Notice:

Pay close attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust or installing the exhaust oil seal to the intake can cause installation problems later.

2. Install intake valve

1. Place the cylinder head on wooden blocks.
2. Install the valve, seat, spring and retainer onto the cylinder head.

3. Using sst, compress the spring, and place the 2 retainer locks around the valve stem.

Sst 09202-70020 (09202-00010)

4. Using a plastic-faced hammer and discarded valve (with its tip wrapped with tape), lightly tap the installed valve to fit it into place.

Notice:

Be careful not to damage the valve stem tip.

3. Install exhaust valve

1. Place the cylinder head on wooden blocks.

2. Install the valve, seat, spring and retainer onto the cylinder head.
3. Using sst, compress the spring, and place the 2 retainer locks around the valve stem.

Sst 09202-70020 (09202-00010)

4. Using a plastic-faced hammer and discarded valve (with its tip wrapped with tape), lightly tap the installed valve to fit it into place.

Notice:

Be careful not to damage the valve stem tip.

4. Install valve lifter

1. Assemble the valve lifter and the tip of the valve stem with a light coat of engine oil applied.

Notice:

Install the valve lifters in their original places.

5. Nstall no. 1 Camshaft bearing

Clean the contact surface of the bearing and the bearing cap.

Notice:

Do not apply engine oil to the contact surfaces of the camshaft bearing and bearing cap.

2. Align the bearing claw with the claw groove of no. 1 And no. 2 Bearing cap, and push in the no. 1 Camshaft bearing.

6. Install no. 2 Camshaft bearing

1. Clean the contact surface of the bearing and the bearing cap.

Notice:

Do not apply engine oil to the contact surfaces of the camshaft bearing and cylinder block.

2. Install the no. 2 Camshaft bearing onto the cylinder head.

7. Install camshaft position sensor

1. Install the camshaft position sensor with the bolt.

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

8. Install engine coolant temperature sensor

1. Using sst, install a new gasket and the ect sensor.

Sst 09817-33190

Torque: 20 n*m (204 kgf*cm, 15 ft.*Lbf)

9. Install oil pressure switch

1. Apply adhesive to 2 or 3 threads of the oil pressure switch.

Adhesive: toyota genuine adhesive 1344, three bond 1344 or equivalent

2. Using a 24 mm deep socket wrench, install the oil pressure switch.

Torque: 13 n*m (133 kgf*cm, 10 ft.*Lbf)

10. Install radio setting condenser

1. Install the condenser with the bolt.

Torque: 10 n*m (102 kgf*cm, 7 ft.*Lbf)