Toyota RAV4 2000-05

Cylinder Head

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Release the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Right-hand engine undercover
     

  6.  
  7. Drain the engine coolant.
  8.  
  9. Remove or disconnect the following:

    Camshafts
     
    Cylinder head bolts in several passes
     
    Cylinder head with the intake manifold
     
    Air hose from the intake manifold
     
    2 bolts and the air tube
     
    Intake manifold and gasket
     
    Air hose from the cylinder head port
     
    Air hose
     
    Fuel delivery pipe and the injectors
     
    Oil pressure switch
     

  10.  

To install:

  1. Install or connect the following:

    Oil pressure switch
     
    Fuel injectors and the delivery pipe
     
    Air hose to the cylinder head port
     
    Intake manifold with new gaskets. Tighten the nut/bolts to 14 ft. lbs. (19 Nm).
     
    Air tube with the 2 bolts
     
    Air hose to the intake manifold
     

  2.  
  3. Clean the gasket mating surfaces using care not to damage the aluminum components, replace the gasket; then, lower the cylinder head onto the engine. Be sure the dowel pins are aligned and no hoses or wires are between the head and cylinder block.

    Click image to see an enlarged view

    Fig. Cylinder head bolts installation sequence-2.0L engine

  4.  
  5. Tighten the cylinder head bolts in 2 progressive steps, as follows:
    1. Apply a light coat of engine oil to the cylinder head bolts.
    2.  
    3. Tighten the cylinder head bolts, in several passes, in sequence, to 36 ft. lbs. (49 Nm).
    4.  
    5. Mark the front of the cylinder head bolt with paint.
    6.  
    7. Retighten the cylinder head bolts by 90 degrees in sequence.
    8.  
    9. Retighten an additional 90 degrees and be sure that the paint mark is now positioned toward the rear.
    10.  

  6.  
  7. Install or connect the following:

    Intake and exhaust camshafts
     
    Negative battery cable
     

  8.  
  9. Refill the engine with coolant, start the engine, warm up and check for leaks.
  10.  
  11. Bleed the cooling system and top off coolant as necessary.
  12.  
  13. Install the right-hand engine undercover.
  14.  
  15. Check ignition timing and road test the vehicle for proper operation.
  16.  

2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Release the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Right-hand engine undercover
     

  6.  
  7. Drain the engine coolant.
  8.  
  9. Remove or disconnect the following:

    Camshafts
     
    Cylinder head bolts in several passes
     
    Cylinder head with the intake manifold
     
    Air hose from the intake manifold
     
    2 bolts and the air tube
     
    Intake manifold and gasket
     
    Air hose from the cylinder head port
     
    Air hose
     
    Fuel delivery pipe and the injectors
     
    Oil pressure switch
     

  10.  

To install:

  1. Install or connect the following:

    Oil pressure switch
     
    Fuel injectors and the delivery pipe
     
    Air hose to the cylinder head port
     
    Intake manifold with new gaskets. Tighten the nut/bolts to 14 ft. lbs. (19 Nm).
     
    Air tube with the 2 bolts
     
    Air hose to the intake manifold
     

  2.  
  3. Clean the gasket mating surfaces using care not to damage the aluminum components, replace the gasket; then, lower the cylinder head onto the engine. Be sure the dowel pins are aligned and no hoses or wires are between the head and cylinder block.
  4.  
  5. For 2000-01, tighten the cylinder head bolts as follows:
    1. Apply a light coat of engine oil to the cylinder head bolts.
    2.  
    3. Tighten the cylinder head bolts, in several passes, in sequence, to 36 ft. lbs. (49 Nm).
    4.  
    5. Mark the front of the cylinder head bolt with paint.
    6.  
    7. Retighten the cylinder head bolts by 90 degrees in sequence.
    8.  
    9. Retighten an additional 90 degrees and be sure that the paint mark is now positioned toward the rear.
    10.  

  6.  
  7. For 2002, tighten the cylinder head bolts in 3 progressive steps, as follows:
    1. Apply a light coat of engine oil to the cylinder head bolts.
    2.  
    3. Tighten the cylinder head bolts, in sequence, to 15 ft. lbs. (26 Nm).
    4.  
    5. Tighten the cylinder head bolts, in sequence, to 30 ft. lbs. (52 Nm).
    6.  
    7. Mark the front of the cylinder head bolt with paint.
    8.  
    9. Retighten the cylinder head bolts by 90 degrees in sequence.
    10.  

  8.  
  9. Install or connect the following:

    Intake and exhaust camshafts
     
    Negative battery cable
     

  10.  
  11. Refill the engine with coolant, start the engine, warm up and check for leaks.
  12.  
  13. Bleed the cooling system and top off coolant as necessary.
  14.  
  15. Install the right-hand engine undercover.
  16.  
  17. Check ignition timing and road test the vehicle for proper operation.
  18.  


    Click image to see an enlarged view

    Fig. Cylinder head bolts installation sequence-2.0L engine


  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Release the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Right side engine undercover
     

  6.  
  7. Drain the engine coolant.
  8.  
  9. Remove or disconnect the following:

    Camshafts
     
    Cylinder head bolts in several passes
     
    Cylinder head with the intake manifold
     
    Air hose from the intake manifold
     
    2 bolts and the air tube
     
    Intake manifold and gasket
     
    Air hose from the cylinder head port
     
    Air hose
     
    Fuel delivery pipe and the injectors
     
    Oil pressure switch
     

  10.  

To install:

  1. Install or connect the following:

    Oil pressure switch
     
    Fuel injectors and the delivery pipe
     
    Air hose to the cylinder head port
     
    Intake manifold with new gaskets. Tighten the nut/bolts to 14 ft. lbs. (19 Nm).
     
    Air tube with the 2 bolts
     
    Air hose to the intake manifold
     

  2.  
  3. Clean the gasket mating surfaces using care not to damage the aluminum components, replace the gasket; then, lower the cylinder head onto the engine. Be sure the dowel pins are aligned and no hoses or wires are between the head and cylinder block.

    Click image to see an enlarged view

    Fig. Cylinder head bolt torque sequence-2.0L engine

  4.  
  5. Tighten the cylinder head bolts in 3 progressive steps, as follows:
    1. Apply a light coat of engine oil to the cylinder head bolts.
    2.  
    3. Tighten the cylinder head bolts, in sequence, to 15 ft. lbs. (26 Nm).
    4.  
    5. Tighten the cylinder head bolts, in sequence, to 30 ft. lbs. (52 Nm).
    6.  
    7. Mark the front of the cylinder head bolt with paint.
    8.  
    9. Retighten the cylinder head bolts by 90 degrees in sequence.
    10.  

  6.  
  7. Install or connect the following:

    Intake and exhaust camshafts
     
    Negative battery cable
     

  8.  
  9. Refill the engine with coolant, start the engine, warm up and check for leaks.
  10.  
  11. Bleed the cooling system and top off coolant as necessary.
  12.  
  13. Install the right side engine undercover.
  14.  
  15. Check ignition timing and road test the vehicle for proper operation.
  16.  

 
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