This procedure covers removal and replacement of the crankshaft position sensor on a 2019-2024 Toyota RAV4 with the 2.5L I4 gasoline engine.

Warnings

Tools required

Parts

• Crankshaft Position Sensor × 1 — Use OEM specification
• O-ring seal for sensor (if not included with sensor) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely (minimum 1 hour after operation)
3. Disconnect negative battery terminal and wait 3 minutes before proceeding
4. If vehicle has an engine undertray, it may need to be removed for better access (varies by trim level)

Procedure

1. 1

   Locate the crankshaft position sensor
   The crankshaft position sensor is located on the passenger side of the engine block, near the oil pan and behind the lower timing cover area. It is positioned approximately level with the crankshaft pulley. Use a flashlight to identify the sensor and its electrical connector from above or below the vehicle.
2. 2

   Disconnect the electrical connector
   Press the locking tab on the crankshaft position sensor electrical connector and pull the connector straight away from the sensor. The connector may be stiff due to age or heat exposure. Do not pull on the wires themselves. Wiggle the connector gently while pulling if it is stuck.
3. 3

   Remove the sensor mounting bolt
   Using a 10mm socket with extension, remove the single bolt securing the crankshaft position sensor to the engine block. Keep track of this bolt as it is small and easily lost. The bolt is accessible from above on the passenger side of the engine, though access is tight.
   Torque spec

   Crankshaft Position Sensor10 Nm (7 lb-ft)
4. 4

   Extract the sensor from the engine block
   Carefully pull the crankshaft position sensor straight out of its bore in the engine block. The sensor may be tight due to the O-ring seal. Gently twist and pull if necessary, but avoid excessive force. Once removed, inspect the sensor tip for any metal debris or damage.
5. 5

   Clean the sensor mounting bore
   Use a clean shop towel to wipe any dirt, oil residue, or debris from the sensor mounting bore in the engine block. Inspect the bore for any damage or contamination. Ensure the area is clean and dry before installing the new sensor.
6. 6

   Prepare the new sensor
   Inspect the new crankshaft position sensor and verify it has an O-ring seal installed. If the O-ring is separate, install it onto the sensor body in the appropriate groove. Lightly lubricate the O-ring with clean engine oil to ease installation and prevent damage.
7. 7

   Install the new sensor
   Carefully insert the new crankshaft position sensor into the engine block bore, ensuring proper alignment. Push the sensor in fully until it seats completely against the mounting surface. The sensor should slide in smoothly with light pressure once the O-ring passes into the bore.
8. 8

   Install and torque the mounting bolt
   Thread the mounting bolt by hand to ensure proper engagement, then tighten to the specified torque of 10.0 Nm (7.0 lb-ft) using a torque wrench. Do not overtighten as this can damage the sensor housing or threads in the aluminum engine block.
   Torque spec

   Crankshaft Position Sensor10 Nm (7 lb-ft)
9. 9

   Reconnect the electrical connector
   Push the electrical connector onto the crankshaft position sensor until you hear or feel a positive click, indicating the locking tab has engaged. Gently tug on the connector to verify it is securely locked in place.
10. 10

    Reinstall undertray if removed
    If the engine undertray was removed for access, reinstall it using the appropriate fasteners. Ensure all clips and bolts are properly secured.
11. 11

    Reconnect battery and clear codes
    Reconnect the negative battery terminal. If available, use an OBD-II scanner to clear any stored diagnostic trouble codes related to the crankshaft position sensor (typically P0335, P0336, or P0338). If no scanner is available, the check engine light should turn off after successful sensor operation.

Reassembly

1. Ensure the electrical connector is fully seated and locked
2. Verify the sensor mounting bolt is torqued to specification and not over-tightened
3. Double-check that all tools and materials have been removed from the engine bay

Verification

• Start the engine and verify it starts normally without extended cranking or rough idle
• Confirm that no check engine light appears or that previous crankshaft sensor codes do not return
• Allow engine to idle for 2-3 minutes and verify smooth operation
• If equipped with an OBD-II scanner, verify that crankshaft position sensor data is being received (typically displays RPM)
• Test drive the vehicle to confirm normal acceleration and no hesitation or stalling occurs

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