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:

Preparations to use wireless communication
The following can be performed using bluetooth® wireless communication: A portable audio player can be operated and listened to via audio system Hands-free phone calls can be made via a cellular phone In order to use wireless communication, register and connect a bluetooth® device by p ...

Installation (2006/01- )
Install front drive shaft assembly lh Coat the spline of the inboard joint shaft with gear oil. Align the shaft splines and tap in the drive shaft with a brass bar and hammer. Notice: Set the snap ring with the opening side facing downwards. Be careful not to damage the ...

Exhaust pipe
Components 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 heated oxygen sensor (for bank 1 sensor 2) (s ...

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