Toyota RAV4 2000-05

Timing Chain Cover & Seal

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the oil.
  6.  
  7. Remove the right under cover.
  8.  
  9. Remove the power steering pump.
  10.  
  11. Disconnect the brake lines and remove the ABS actuator. Plug the lines.
  12.  
  13. Remove the right engine mount insulator.
  14.  
  15. Remove the accessory drive belt.
  16.  
  17. Remove the alternator.
  18.  
  19. Remove the air cleaner assembly.
  20.  
  21. Remove the ignition coils.
  22.  
  23. Remove the cylinder head cover.
  24.  
  25. Turn the crankshaft clockwise and align the groove in the pulley with the -0- mark on the timing cover. Check that the timing marks on the cam sprockets align with the timing marks on the Nos. 1 and 2 bearing caps. If the marks don-t align, turn the crankshaft one full turn (360 degrees) clockwise.
  26.  
  27. Remove the crank pulley.
  28.  
  29. Remove the chain tensioner.
  30.  
  31. Remove the drive belt tensioner.
  32.  
  33. Remove the crankshaft position sensor.
  34.  
  35. Remove the oil pan.
  36.  
  37. Remove the timing chain cover (14 bolts and 2 nuts)
  38.  
  39. Remove the oil seal from the cover, using a hammer and punch.
  40.  

To install:

  1. Drive a new seal into place with a seal installer until it is flush with the cover. Coat the seal lip with multi-purpose grease.
  2.  
  3. Clean all traces of old gasket material from the mating surfaces. Apply a 4mm diameter bead of RTV gasket material to the cover mating surface. Apply sealer to the 2 areas where the crankcase and block meet. The cover must be installed with 3-5 minutes of applying the sealer.

    Click image to see an enlarged view

    Fig. Apply sealer to the 2 areas where the crankcase and block meet-2.4L engine



    Click image to see an enlarged view

    Fig. Cover bolt identification-2.4L engine

  4.  
  5. Install the cover and torque the bolts as shown in the accompanying illustration. Bolt A 10 mm bolts are torqued to 80 inch lbs. (9 Nm); bolt B 12mm bolts are torqued to 15 ft. lbs. (21 Nm); bolts C and D 14mm bolts are torqued to 32 ft. lbs. (43 Nm); the nuts are torqued to 80 inch lbs. (9 Nm).
  6.  
  7. Install the tensioner stud bolt. Torque to 16 ft. lbs. (21 Nm).
  8.  
  9. Install the drive belt tensioner. Torque to 44 ft. lbs. (60 Nm).
    NOTE
    The drive belt tensioner should be installed within 15 minutes of the timing cover.

  10.  
  11. Install the crankshaft position sensor.
  12.  
  13. Install the oil pan.

    Click image to see an enlarged view

    Fig. Push in the plunger-2.4L engine



    Click image to see an enlarged view

    Fig. Correct gasket positioning-2.4L engine

  14.  
  15. Install the chain tensioner. The plunger should be held retracted until the tensioner is installed. The gasket should be positioned as shown. Torque to 80 inch lbs. (9 Nm).
  16.  
  17. Turn the crankshaft counterclockwise and release the tensioner plunger. Turn the crank clockwise and check that the slipper is pushed by the plunger.
  18.  
  19. Turn the crank puller clockwise so that the notch in the crank pulley is aligned with the -0- mark on the timing cover. Check that all timing marks are aligned. If not, turn it 1 full turn clockwise and check again.
  20.  
  21. Install the cylinder head cover.
  22.  
  23. Install the ignition coils.
  24.  
  25. Install the power steering pump.
  26.  
  27. Install the alternator.
  28.  
  29. Install the engine mount insulator.
  30.  
  31. Install the ABS actuator. Torque the brake lines to 11 ft. lbs. (15 Nm); the mounting bolts to 48 inch lbs. (5 Nm). Bleed the brakes.
  32.  
  33. Install the air cleaner.
  34.  
  35. Install the under cover.
  36.  
  37. Refill the engine oil.
  38.  

2.4L Engine


Click image to see an enlarged view

Fig. Timing chain and related parts-2.4L engine

  1. Drain the oil.
  2.  
  3. Remove the right under-cover.
  4.  
  5. Remove the power steering pump.
  6.  
  7. Disconnect the brake lines and remove the ABS actuator. Plug the lines.
  8.  
  9. Remove the right engine mount insulator.
  10.  
  11. Remove the accessory drive belt.
  12.  
  13. Remove the alternator.
  14.  
  15. Remove the air cleaner assembly.
  16.  
  17. Remove the ignition coils.
  18.  
  19. Remove the cylinder head cover.
  20.  
  21. Turn the crankshaft clockwise and align the groove in the pulley with the -0- mark on the timing cover. Check that the timing marks on the cam sprockets align with the timing marks on the Nos. 1 and 2 bearing caps. If the marks don-t align, turn the crankshaft one full turn (360 degrees) clockwise.
  22.  
  23. Remove the crank pulley.
  24.  
  25. Remove the chain tensioner.
  26.  
  27. Remove the drive belt tensioner.
  28.  
  29. Remove the crankshaft position sensor.
  30.  
  31. Remove the oil pan.
  32.  
  33. Remove the timing chain cover (14 bolts and 2 nuts)
  34.  
  35. Remove the crank angle sensor plate.
  36.  
  37. Remove the chain tension slipper.
  38.  
  39. Remove the chain vibration damper.
  40.  
  41. Remove the chain guide.
  42.  
  43. Remove the timing chain.
  44.  
  45. Remove the crankshaft timing sprocket.
  46.  
  47. Remove the oil seal from the cover, using a hammer and punch.
  48.  

To install:

  1. Drive a new seal into place with a seal installer until it is flush with the cover. Coat the seal lip with multi-purpose grease.
  2.  
  3. Check the timing chain with the chain full stretched. The length of 16 consecutive links should be 122.6mm (4.827 inches) max. If it-s longer than that, replace it.
  4.  
  5. Install the camshaft sprocket. Torque to 40 ft. lbs. (54 Nm).
  6.  
  7. Position the VVT sprocket so that the sprocket pin groove is slight right of the camshaft pin. Press the VVT into place turning it counterclockwise.
  8.  
  9. Install the bolt and torque to 40 ft. lbs. (54 Nm). Check that the valve timing controller turns clockwise and that it is locked securely when the lock pin hole is at the locking point.
  10.  
  11. Turn the camshafts so that the timing marks on the cam sprockets align with the timing marks on the Nos. 1 and 2 bearing caps. If the marks don-t align, turn the crankshaft one full turn (360 degrees) clockwise.
  12.  
  13. Turn the crankshaft so that the key is at the 12:00 o-clock position.
  14.  
  15. Install the chain vibration damper. Torque to 80 inch lbs. (9 Nm).
  16.  
  17. Install the crank timing sprocket.
  18.  
  19. Install the timing chain on the crank sprocket with the blue or orange link is aligned with the timing mark on the crank sprocket.
  20.  
  21. Install the timing chain on the camshaft sprockets with the gold or yellow links aligned with the timing marks on the sprockets.
  22.  
  23. Install the timing chain guide. Torque to 80 inch lbs. (9 Nm).
  24.  
  25. Install the chain tension slipper. Torque to 14 ft. lbs. (19 Nm).
  26.  
  27. Install the crank angle sensor plate with the -F- mark facing forward.
  28.  
  29. Clean all traces of old gasket material from the mating surfaces. Apply a 4mm diameter bead of RTV gasket material to the cover mating surface. Apply sealer to the 2 areas where the crankcase and block meet. The cover must be installed with 3-5 minutes of applying the sealer.
  30.  
  31. Install the cover and torque the bolts as shown in the accompanying illustration. Bolt A 10 mm bolts are torqued to 80 inch lbs. (9 Nm); bolt B 12mm bolts are torqued to 15 ft. lbs. (21 Nm); bolts C and D 14mm bolts are torqued to 32 ft. lbs. (43 Nm); the nuts are torqued to 80 inch lbs. (9 Nm).
  32.  
  33. Install the tensioner stud bolt. Torque to 16 ft. lbs. (21 Nm).
  34.  
  35. Install the drive belt tensioner. Torque to 44 ft. lbs. (60 Nm).
  36.  


    Click image to see an enlarged view

    Fig. Position the VVT sprocket so that the sprocket pin groove is slight right of the camshaft pin-2.4L engine



    Click image to see an enlarged view

    Fig. Turn the camshafts so that the timing marks on the cam sprockets align with the timing marks on the Nos. 1 and 2 bearing caps-2.4L engine



    Click image to see an enlarged view

    Fig. Install the timing chain on the crank sprocket with the blue or orange link is aligned with the timing mark on the crank sprocket-2.4L engine



    Click image to see an enlarged view

    Fig. Install the timing chain on the camshaft sprockets with the gold or yellow links aligned with the timing marks on the sprockets-2.4L engine



    Click image to see an enlarged view

    Fig. Apply sealer to the 2 areas where the crankcase and block meet-2.4L engine



    Click image to see an enlarged view

    Fig. Cover bolt identification-2.4L engine



NOTE
The drive belt tensioner should be installed within 15 minutes of the timing cover.

  1. Install the crankshaft position sensor.
  2.  
  3. Install the oil pan.
  4.  
  5. Install the chain tensioner. The plunger should be held retracted until the tensioner is installed. The gasket should be positioned as shown. Torque to 80 inch lbs. (9 Nm).
  6.  
  7. Turn the crankshaft counterclockwise and release the tensioner plunger. Turn the crank clockwise and check that the slipper is pushed by the plunger.
  8.  
  9. Turn the crank puller clockwise so that the notch in the crank pulley is aligned with the -0- mark on the timing cover. Check that all timing marks are aligned. If not, turn it 1 full turn clockwise and check again.
  10.  
  11. Install the cylinder head cover.
  12.  
  13. Install the ignition coils.
  14.  
  15. Install the PS pump.
  16.  
  17. Install the alternator.
  18.  
  19. Install the engine mount insulator.
  20.  
  21. Install the ABS actuator. Torque the brake lines to 11 ft. lbs. (15 Nm); the mounting bolts to 48 inch lbs. (5 Nm). Bleed the brakes.
  22.  
  23. Install the air cleaner.
  24.  
  25. Install the under-cover.
  26.  
  27. Refill the engine oil.
  28.  


    Click image to see an enlarged view

    Fig. Push in the plunger-2.4L engine



    Click image to see an enlarged view

    Fig. Correct gasket positioning-2.4L engine


 
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