Toyota RAV4 manuals

Toyota RAV4 Service Manual: Replacement

  1. Replace timing chain cover oil seal

Hint:

There are 2 methods to replace the oil seal.

  1. If the timing chain cover is removed from the cylinder block:
  1. Using a screwdriver and hammer, tap out the oil seal.
  2. Apply multi-purpose grease to the lip of a new oil seal.

Toyota RAV4. Replace timing chain cover oil seal


Notice:

Keep the lip free of foreign objects.

  1. Using sst and a hammer, tap in the new oil seal until its surface is flush with the timing chain cover edge.

Sst 09223-22010

Toyota RAV4. Replace timing chain cover oil seal


Notice:

Do not tap the oil seal at an angle.

  1. If the timing chain cover oil seal is installed to the cylinder block:
  1. Remove the fan and generator v belt (see page em-6).
  2. Remove the crankshaft pulley (see page em- 25).
  3. Using a knife, cut off the lip of the oil seal.
  4. Using a screwdriver with its tip wrapped with tape, pry out the oil seal.

Notice:

After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper.

Toyota RAV4. Replace timing chain cover oil seal


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

Notice:

Keep the lip free of foreign objects.

  1. Using sst and a hammer, tap in the new oil seal until its surface is flush with the timing chain cover edge.

Sst 09223-22010

Toyota RAV4. Replace timing chain cover oil seal


Notice:

Do not tap the oil seal at an angle.

  1. Install the crankshaft pulley (see page em-38).
  2. Install the fan and generator v belt (see page em-7).
  1. Replace engine rear oil seal

Toyota RAV4. Replace engine rear oil seal


  1. Using a knife, cut off the lip of the oil seal.
  2. Using a screwdriver with its tip wrapped with tape, pry out the oil seal.

Notice:

After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper.

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

Notice:

Keep the lip free of foreign objects.

Toyota RAV4. Replace engine rear oil seal


  1. Using sst and a 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)

Notice:

  1. Replace stud bolt (for cylinder block)

Notice:

If the stud bolt is deformed or the threads are damaged, replace it.

  1. Remove the 8 stud bolts.
  2. Install the 8 stud bolts into the cylinder block.

Torque


Toyota RAV4. Replace stud bolt (for cylinder block)


  1. Replace tight plug (for cylinder block)

Notice:

If water leaks from the tight plug or the plug corrodes, replace it.

  1. Remove the 2 tight plugs from the engine front and rear side.
  2. Apply adhesive around new tight plugs.

Adhesive:

Toyota genuine adhesive 1342, three bond 1342 or equivalent

Toyota RAV4. Replace tight plug (for cylinder block)


  1. Using sst, install the 2 tight plugs.

Sst 09950-60010 (09951-00200), 09950-70010 (09951-07100)

Standard depth


Toyota RAV4. Replace tight plug (for cylinder block)


  1. Replace ring pin (for cylinder block)

Notice:

It is not necessary to remove with head pin unless it is being replaced.

  1. Remove the 12 ring pins.
  2. Using a plastic-faced hammer, install 12 new ring pins.

Standard protrusion height


Toyota RAV4. Replace ring pin (for cylinder block)


  1. Replace straight pin (for cylinder block)

Notice:

It is not necessary to remove with straight pin unless it is being replaced.

  1. Remove the 8 straight pins.
  2. Using a plastic-faced hammer, install 8 new straight pins.

Standard protrusion height


Toyota RAV4. Replace straight pin (for cylinder block)


Inspection
Inspect cylinder block for warpage Using a precision straightedge and feeler gauge, measure the warpage of the surface that is in contact with the cylinder head gasket. Maximum war ...

Reassembly
Install piston 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 ...

Other materials:

Rear brake flexible hose
Installation Hint: Use the same procedures for the lh side and rh side. The procedures listed below are for the lh side. Install rear brake tube flexible hose Notice: The gasket and union bolt must be used as a set, as shown in the illustration. Connect the flexible hose wi ...

Center airbag sensor assembly malfunction
Description The center airbag sensor consists of the airbag sensor, the safing sensor, the drive circuit, the diagnosis circuit and the ignition control. If the center airbag sensor receives signals from the airbag sensor, it determines whether or not the srs should be activated. Dt ...

Removal
Disconnect cable from negative battery terminal Caution: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. Remove no. 1 Engine cover (see page es-410) Remove air cleaner cap (see pag ...

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