Toyota RAV4 manuals

Toyota RAV4 Service Manual: Reassembly

  1. Install piston

Toyota RAV4. Install piston


  1. Using a small screwdriver, install a new snap ring onto one end of the piston pin hole.

Hint:

Make sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

  1. Gradually heat the piston up to 80 to 90c (176 to 194f).
  2. Align the front marks of the piston and connecting rod, then push in the piston pin with your thumb until the pin comes into contact with the snap pin hole.

Toyota RAV4. Install piston


Hint:

Make sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

  1. Install piston ring set

Toyota RAV4. Install piston ring set


  1. Install the expander and oil ring by hand.
  2. Using a piston ring expander, install the 2 compression rings with the paint mark as shown in the illustration.

Notice:

Install the no. 2 Compression ring with the code mark (2n) facing upward.

Toyota RAV4. Install piston ring set


  1. Position the piston rings so that the ring ends are as shown in the illustration.

Toyota RAV4. Install piston ring set


  1. Install no. 1 Oil nozzle sub-assembly

Toyota RAV4. Install no. 1 Oil nozzle sub-assembly


  1. Install the 4 oil nozzles with the 4 bolts.

Torque: 7.0 N*m (71 kgf*cm, 62 in.*Lbf)

  1. Install cylinder block water jacket spacer

Toyota RAV4. Install cylinder block water jacket spacer


  1. Install crankshaft bearing

Toyota RAV4. Install crankshaft bearing


  1. Install the upper bearing with an oil groove onto the cylinder block.

Notice:

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

  1. Install no. 2 Crankshaft bearing

  1. Install the lower bearing onto the bearing cap.

Toyota RAV4. Install no. 2 Crankshaft bearing


Notice:

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

  1. Install crankshaft thrust washer upper

Toyota RAV4. Install crankshaft thrust washer upper


  1. Install the 2 thrust washers onto the no. 3 Journal position of the cylinder block with the oil groove facing outward.
  1. Install crankshaft

Toyota RAV4. Install crankshaft


  1. Apply engine oil to the upper bearing, and install the crankshaft onto the cylinder block.
  2. Examine the front marks and numbers, and install the bearing caps onto the cylinder block in the order shown in the illustration.
  3. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

Toyota RAV4. Install crankshaft


  1. using several steps, uniformly install and tighten the 10 bearing cap bolts in the sequence shown in the illustration.

Torque: 40 n*m (408 kgf*cm, 30 ft.*Lbf)

Toyota RAV4. Install crankshaft


Toyota RAV4. Install crankshaft


  1. Mark the front of the bearing cap bolts with paint.
  2. Retighten the 10 bearing cap bolts by 90 in the same sequence.
  3. Check that the paint marks are now at a 90 angle to the front.
  4. Check that the crankshaft turns smoothly.
  1. Install connecting rod bearing

Toyota RAV4. Install connecting rod bearing


  1. Align the bearing claw with the oil groove of the connecting rod or connecting rod cap.

Notice:

  1. Install piston with connecting rod

Toyota RAV4. Install piston with connecting rod


  1. Apply engine oil to the cylinder walls, pistons, and surfaces of connecting rod bearings.
  2. Check the position of the piston ring ends.

Toyota RAV4. Install piston with connecting rod


  1. Using a hammer handle and piston ring compressor, press a piston and connecting rod into each cylinder with the front mark of the piston facing forward.
  2. Check that the front mark of the connecting rod cap is facing in the correct direction.

Toyota RAV4. Install piston with connecting rod


Notice:

Match the numbered connecting rod cap with the connecting rod.

  1. Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.
  2. Using a 12 mm socket wrench, tighten the bolts in several passes to the specified torque.

Torque: 24.5 N*m (250 kgf*cm, 18 ft.*Lbf)

  1. Mark the front of the connecting rod bolts with paint.
  2. Retighten the cap bolts 90 as shown in the illustration.
  3. Check that the crankshaft turns smoothly.

Toyota RAV4. Install piston with connecting rod


  1. Install no. 1 Balance shaft bearing

  1. Align the bearing claw with the claw groove, and push in the 8 bearings.

Toyota RAV4. Install no. 1 Balance shaft bearing


Notice:

  1. Apply light coat of engine oil to the bearings.
  1. Install balance shaft

Toyota RAV4. Install balance shaft


  1. Rotate the no. 1 Driven gear of the no. 1 Balance shaft in the rotating direction until it hits the stopper.

Toyota RAV4. Install balance shaft


  1. Confirm that the timing marks on the no. 1 And no.

    2 Driven gears are aligned.

Toyota RAV4. Install balance shaft


  1. Align the timing marks of the no. 1 And no. 2 Balance shafts as shown in the illustration.
  2. Place the no. 1 And no. 2 Balance shafts onto the crankcase.
  3. Apply a light coat of engine oil to the threads and under the heads of the bolts.

Toyota RAV4. Install balance shaft


  1. Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.

Torque: 21.6 N*m (220 kgf*cm, 16 ft.*Lbf)

  1. Mark the front of the bolts with paint.
  2. Retighten the bolts 90 as shown in the illustration.
  3. Check that the paint mark is now at a 90 angle to the front.
  1. Install stiffening crankcase assembly

Toyota RAV4. Install stiffening crankcase assembly


  1. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and crankcase.

Toyota RAV4. Install stiffening crankcase assembly


  1. Place a new o-ring on the cylinder block as shown in the illustration.

Toyota RAV4. Install stiffening crankcase assembly


  1. With the no. 1 Crank pin of the crankshaft placed at the 6 o'clock position, install the no. 1 And no. 2 Balance shafts and align the adjusting holes as shown in the illustration.

Toyota RAV4. Install stiffening crankcase assembly


  1. Apply a continuous bead of seal packing (diameter 2.5 To 3.0 Mm (0.098 To 0.118 In.)) As shown in the illustration.

Seal packing: toyota genuine seal packing black, three bond 1207b or equivalent

Notice:

  1. Temporarily install the crankcase with the 11 bolts.

Toyota RAV4. Install stiffening crankcase assembly


Standard bolt length


  1. Uniformly tighten the bolts.

Toyota RAV4. Install stiffening crankcase assembly


Torque: 24 n*m (245 kgf*cm, 18 ft.*Lbf)

  1. Confirm that the timing marks of the balance shafts are aligned when the key groove is placed at the 6 o'clock position, as shown in the illustration.

Toyota RAV4. Install stiffening crankcase assembly


  1. Install engine rear oil seal

  1. Apply multi-purpose grease to the lip of a new oil seal.

Toyota RAV4. Install engine rear oil seal


Notice:

Keep the lip free of foreign object.

  1. Using sst and hammer, tap in the new oil seal until its surface is flush with the rear oil seal retainer edge.

Sst 09223-15030, 09950-70010 (09951-07100)

Toyota RAV4. Install engine rear oil seal


Notice:

  1. Install oil control valve filter

Toyota RAV4. Install oil control valve filter


  1. Check that there are no foreign objects on the mesh part of the oil control valve filter.
  2. Using a 6 mm socket hexagon wrench, install a new gasket and the oil control valve filter with the plug.

Torque: 30 n*m (306 kgf*cm, 22 ft.*Lbf)

  1. Install cylinder block water drain cock sub-assembly

  1. Apply adhesive to 2 or 3 threads of the drain cock.

Toyota RAV4. Install cylinder block water drain cock sub-assembly


Adhesive: toyota genuine adhesive 1324, three bond 1324 or equivalent

  1. After tightening the drain cock to the specified torque, turn the drain cock clockwise as shown in the illustration.

Toyota RAV4. Install cylinder block water drain cock sub-assembly


Torque: 25 n*m (255 kgf*cm, 18 ft.*Lbf)

Notice:

  1. Install cylinder head gasket (see page em- 82)

  2. Install cylinder head sub-assembly (see page em-82)

  3. Install camshaft timing oil control valve assembly

Toyota RAV4. Install camshaft timing oil control valve assembly


  1. Apply a light coat of engine oil to a new o-ring, then install it onto the camshaft timing oil control valve.
  2. Install the camshaft timing oil control valve with the bolt.

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

Toyota RAV4. Install camshaft timing oil control valve assembly


  1. Install camshaft timing gear assembly (see page em-83)

  2. Install no. 2 Camshaft timing sprocket (see page em-84)

  3. Install no. 2 Camshaft bearing (see page em- 81)

  4. Install no. 1 Camshaft bearing (see page em- 81)

  5. Install camshaft (see page em-84)

  6. Install oil pump assembly (see page lu-15)

  7. Install oil pump drive gear

  8. Install no. 2 Chain sub-assembly (see page em-32)

  9. Install crankshaft timing sprocket

Toyota RAV4. Install crankshaft timing sprocket


  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. Replace timing chain cover oil seal (see page em-144)

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

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

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

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

  11. Install oil pan drain plug

Toyota RAV4. Install oil pan drain plug


  1. Place a new gasket on the oil pan drain plug, then install it onto the oil pan.

Torque: 40 n*m (408 kgf*cm, 30 ft.*Lbf)

  1. Install water pump assembly (see page co- 12)

  2. Install water pump pulley (see page co-13)

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

  4. Install oil filter union

Toyota RAV4. Install oil filter union


  1. Using a 12 mm hexagon wrench, install the oil filter union.

Torque: 29.5 N*m (301 kgf*cm, 22 ft.*Lbf)

  1. Install oil filter sub-assembly (see page lu- 4)

  2. Set no. 1 Cylinder to tdc/compression (see page em-25)

  3. Check valve clearance (see page em-8)

  4. Adjust valve clearance (see page em-8)

  5. Install camshaft (see page em-13)

  6. Install no. 2 Camshaft (see page em-14)

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

  8. Install cylinder head cover gasket

Toyota RAV4. Install cylinder head cover gasket


  1. Install the gasket onto the cylinder head cover.
  1. Install cylinder head cover sub-assembly (see page em-40)

Toyota RAV4. Install cylinder head cover sub-assembly (see page em-40)


  1. Install oil filler cap sub-assembly

Toyota RAV4. Install oil filler cap sub-assembly


  1. Install the gasket to the cap.
  2. Install the oil filler cap.

Toyota RAV4. Install oil filler cap sub-assembly


Torque: 3.0 N*m (31 kgf*cm, 26 in.*Lbf)

  1. Install spark plug

Toyota RAV4. Install spark plug


Torque: 25 n*m (254 kgf*cm, 18 ft.*Lbf)

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

  2. Install ventilation valve sub-assembly

Toyota RAV4. Install ventilation valve sub-assembly


  1. Apply adhesive to the threads of the ventilation valve.

Adhesive:

Toyota genuine adhesive 1324, three bond 1324 or equivalent

  1. Using a 22 mm deep socket wrench, install the ventilation valve.

Torque: 19 n*m (194 kgf*cm, 14 ft.*Lbf)

Toyota RAV4. Install ventilation valve sub-assembly


  1. Install oil dipstick guide (see page em-86)

  2. Install oil dipstick

  3. Install camshaft position sensor (see page em-81)

  4. Install engine coolant temperature sensor (see page em-82)

  5. Install oil pressure switch assembly (see page em-82)

  6. Install radio setting condenser (see page em-82)

  7. Install knock sensor (see page es-420)

  8. Install camshaft timing oil control valve assembly (see page es-396)

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

  10. Install no. 3 Water by-pass pipe

Toyota RAV4. Install no. 3 Water by-pass pipe


  1. Install a new gasket and pipe with the bolt and 2 nuts.

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

  1. Install no. 1 Water by-pass pipe

  1. Install a new gasket and the pipe with the bolt and 2 nuts.

Toyota RAV4. Install no. 1 Water by-pass pipe


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

  1. Install thermostat (see page co-15)

  2. Install water inlet (see page co-16)

  3. Install exhaust manifold converter subassembly (see page em-85)

  4. Install no. 1 Exhaust manifold heat insulator (see page em-86)

  5. Install no. 2 Manifold stay (see page em-86)

  6. Install manifold stay (see page em-86)

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

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