Complete removal and replacement of the crankshaft on a 2019-2024 Toyota RAV4 2.5L I4 engine, requiring engine removal, complete disassembly of lower end components, and precision reassembly with torque-to-yield fasteners.

Warnings

Tools required

Parts

• Crankshaft (new or reground to specification) × 1 — Use OEM specification
• Main bearing set (standard or appropriate oversize) × 1 — Use OEM specification
• Connecting rod bearing set (standard or appropriate oversize) × 1 — Use OEM specification
• Front crankshaft main seal × 1 — Use OEM specification
• Rear crankshaft main seal × 1 — Use OEM specification
• Main bearing cap bolts (TTY) × 10 — Use OEM specification
• Connecting rod bolts (TTY) × 8 — Use OEM specification
• Crankshaft pulley bolt × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Timing chain kit (chain, guides, tensioner) × 1 — Use OEM specification
• Cylinder head gasket set × 1 — Use OEM specification
• Oil pump seal/gasket × 1 — Use OEM specification
• Engine oil filter × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• RTV silicone gasket maker (Toyota FIPG or equivalent) × 1 — Use OEM specification
• Complete engine gasket set × 1 — Use OEM specification
• Thrust washers (if applicable) × 1 — Use OEM specification

Fluids

• Toyota Genuine 0W-20 engine oil — 5 qt
• Toyota Super Long Life Coolant (Pink) — 10 qt
• Toyota WS ATF (if transmission removed) — 10 qt

Preparation

1. Disconnect negative battery terminal and wait 90 seconds for airbag system to deplete
2. Drain engine oil completely and remove oil filter
3. Drain engine coolant from radiator and engine block drain plugs
4. Remove engine cover and air intake system completely
5. Remove front wheels and raise vehicle on lift or jack stands rated for extended work
6. Remove front bumper cover, radiator support, and radiator assembly
7. Disconnect all electrical connectors from engine, labeling each for reinstallation
8. Disconnect fuel supply and return lines (relieve fuel pressure first)
9. Remove exhaust manifold and front exhaust pipe assembly
10. Support transmission with transmission jack
11. Remove transmission-to-engine mounting bolts (FWD: transmission stays in vehicle)
12. Disconnect all vacuum lines, coolant hoses, and remaining accessories from engine
13. Remove engine mount bolts and attach engine hoist with proper lift points
14. Carefully lift engine from vehicle and mount securely on engine stand
15. Position engine stand for easy access to bottom end components
16. Clean exterior of engine thoroughly before disassembly

Procedure

1. 1

   Remove valve cover and cylinder head
   Remove valve cover, then remove cylinder head bolts in reverse of tightening sequence (consult service manual for sequence diagram). Lift cylinder head from block and place on clean padded surface. Remove cylinder head gasket and inspect head bolt condition.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
2. 2

   Remove timing components
   Remove timing chain cover bolts (both 8mm and 10mm sizes) in proper sequence. Remove timing chain tensioner, guides, and timing chain. Remove crankshaft timing sprocket. Keep all components organized for inspection and potential reuse of non-wear items.
   Torque spec

   Cover Bolts16 Nm (12 lb-ft)

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

   Timing Chain Guide Bolts12 Nm (9 lb-ft)
3. 3

   Remove crankshaft pulley and front seal housing
   Use impact wrench to remove crankshaft pulley bolt (harmonic balancer bolt). Remove crankshaft pulley. Remove front main seal housing bolts and carefully remove housing. Discard front crankshaft seal.
   Torque spec

   Harmonic Balancer Bolt180 Nm (133 lb-ft)

   Front Main Seal Housing12 Nm (9 lb-ft)
4. 4

   Remove oil pan and oil pickup
   Remove all oil pan bolts and carefully separate oil pan from engine block (may require gentle prying at designated points). Remove oil pump pickup tube fastener and remove pickup tube. Clean all gasket surfaces thoroughly.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)

   Oil Pump Pickup Tube12 Nm (9 lb-ft)
5. 5

   Remove oil pump
   Remove oil pump mounting bolts and remove oil pump assembly from front of engine block. Inspect oil pump for wear or damage. Clean mounting surface on engine block.
   Torque spec

   Oil Pump Bolts12 Nm (9 lb-ft)
6. 6

   Mark and remove pistons with connecting rods
   Mark each connecting rod cap and rod with cylinder number and orientation (use punch marks on non-thrust side). Remove connecting rod bolts and carefully remove rod caps. Push each piston/rod assembly out top of block, keeping caps matched with correct rods. Store in order.
   ⚠Connecting rod caps must be reinstalled on exact same rod in same orientation. Mark clearly before removal to prevent assembly errors.
   Torque spec

   Connecting Rod Bolts45 Nm (33 lb-ft)
7. 7

   Remove main bearing caps and extract crankshaft
   Verify all main bearing caps are clearly marked with position number and directional arrow (mark if not present). Remove main bearing cap bolts in reverse order of tightening sequence. Carefully remove each main bearing cap, keeping them in exact order. Carefully lift crankshaft straight up and out of engine block. Remove thrust washers if present.
   ⚠️Main bearing caps are machined as matched sets with the block and are NOT interchangeable. Installing caps in wrong position will destroy engine. Verify all position markings before removal.
   Torque spec

   Main Bearing Cap Bolts75 Nm (55 lb-ft)
8. 8

   Inspect crankshaft and measure journals
   Clean crankshaft thoroughly with solvent and compressed air (blow out all oil passages). Inspect all journals for scoring, heat discoloration, or damage. Using micrometers, measure all main and rod journals for out-of-round, taper, and undersize condition. Compare measurements to service specifications. If journals are worn beyond specification, crankshaft must be reground to next undersize or replaced.
   ℹ️Toyota specification for crankshaft main journals is approximately 48.00mm diameter with maximum taper of 0.01mm and out-of-round of 0.01mm. Rod journals are approximately 41.00mm. Consult factory service manual for exact specifications and limits.
9. 9

   Inspect engine block bearing bores
   Remove all old bearing shells from block and caps. Clean bearing saddles thoroughly. Using dial bore gauge, measure all main bearing bores for out-of-round and taper. Verify measurements are within specification. Inspect block for cracks or damage.
   ⚠Main bearing bore out-of-round or taper beyond specification requires engine block machining or replacement. Do not attempt assembly with out-of-specification bores.
10. 10

    Install new main bearings and test fit crankshaft
    Install new main bearing shells into engine block saddles and main bearing caps (ensure bearing tangs engage notches properly). Lubricate bearings with clean engine oil. Carefully lower crankshaft into position. Install main bearing caps in correct position and orientation. Install NEW main bearing cap bolts finger-tight only.
    ℹ️Upper and lower bearing shells may be different. Verify correct bearing half is installed in block versus cap. Bearings with oil holes go in block.
11. 11

    Check main bearing clearances with Plastigage
    Remove main caps again. Place Plastigage strips across each crankshaft main journal (do not rotate crankshaft with Plastigage in place). Reinstall main caps with NEW bolts and torque to 75 Nm (55 lb-ft) specification only (do not apply angle yet). Remove caps and measure Plastigage width using scale on package. Clearance should be 0.02-0.04mm (0.0008-0.0016 inch) typical. If out of specification, verify bearing size and crankshaft journal size.
    ⚠️Main bearing clearance outside specification will cause bearing failure and engine seizure. Replace bearings or machine crankshaft as necessary to achieve proper clearance.
    Torque spec

    Main Bearing Cap Bolts75 Nm (55 lb-ft)
12. 12

    Perform final crankshaft installation
    Remove main caps one final time and clean all Plastigage residue. Lubricate all main bearings liberally with clean engine oil. Lubricate crankshaft journals with engine assembly lube. Install crankshaft and install main caps in correct order and orientation with NEW main bearing cap bolts. Torque main cap bolts in sequence to 75 Nm (55 lb-ft), then tighten additional 90 degrees in same sequence. Verify crankshaft rotates freely with no binding.
    ⚠️Main bearing cap bolts are torque-to-yield and must be replaced. Follow torque sequence exactly as specified in service manual. Improper torque or sequence will cause bearing failure.
    Torque spec

    Main Bearing Cap Bolts75 Nm (55 lb-ft)
13. 13

    Install connecting rod bearings and check clearances
    Install new rod bearing shells in connecting rods and caps. Place Plastigage on each crankshaft rod journal. Install pistons/rods back into correct cylinders with ring compressor. Install rod caps in correct orientation with NEW rod bolts torqued to 45 Nm (33 lb-ft) only (no angle yet). Remove caps and measure Plastigage. Rod bearing clearance should be 0.02-0.04mm typical. Clean Plastigage residue.
    ⚠Ensure piston ring gaps are properly staggered and piston orientation mark faces front of engine. Incorrect piston installation will cause engine damage.
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
14. 14

    Final connecting rod installation
    Lubricate rod bearings and journals with engine assembly lube. Install pistons into cylinders with ring compressor, ensuring connecting rods align with crankshaft journals. Install rod caps in correct orientation with NEW connecting rod bolts. Torque rod bolts to 45 Nm (33 lb-ft) plus additional 90 degrees rotation. Verify crankshaft rotates smoothly after each rod installation.
    ⚠️Connecting rod bolts are torque-to-yield and must be replaced with new bolts. Reused rod bolts will fail causing catastrophic engine damage.
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
15. 15

    Install oil pump, rear seal, and oil pan
    Install new rear main seal into housing using seal driver. Install rear main seal housing with new gasket/RTV and torque bolts to 12 Nm (9 lb-ft). Install oil pump with new seal/gasket and torque bolts to 12 Nm (9 lb-ft). Install oil pickup tube with new O-ring and torque to 12 Nm (9 lb-ft). Apply RTV to oil pan mating surface as specified and install oil pan, torquing bolts in sequence to 12 Nm (9 lb-ft).
    Torque spec

    Rear Main Seal Housing12 Nm (9 lb-ft)

    Oil Pump Bolts12 Nm (9 lb-ft)

    Oil Pump Pickup Tube12 Nm (9 lb-ft)

    Oil Pan Bolts12 Nm (9 lb-ft)
16. 16

    Install front seal housing and timing components
    Install new front crankshaft seal into front seal housing using seal driver. Install front seal housing with new gasket and torque bolts to 12 Nm (9 lb-ft). Install crankshaft timing sprocket. Install timing chain with proper alignment marks matched. Install timing chain guides and torque bolts to 12 Nm (9 lb-ft). Compress timing chain tensioner, install locking pin, install tensioner and torque bolt to 25 Nm (18 lb-ft), then release pin.
    Torque spec

    Front Main Seal Housing12 Nm (9 lb-ft)

    Timing Chain Guide Bolts12 Nm (9 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
17. 17

    Install timing cover and crankshaft pulley
    Apply RTV sealant to timing cover mating surfaces as specified in service manual. Install timing cover and torque 8mm bolts to 25 Nm (18 lb-ft) and 10mm bolts to 45 Nm (33 lb-ft) in proper sequence. Install crankshaft pulley and torque NEW crankshaft pulley bolt to 180 Nm (133 lb-ft) using impact wrench or holding tool.
    ℹ️Crankshaft pulley bolt is often TTY. Verify specification and replace if required. Use impact wrench or proper holding tool to achieve torque specification.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)

    Crankshaft Pulley Bolt180 Nm (133 lb-ft)
18. 18

    Install cylinder head
    Clean cylinder head and block mating surfaces thoroughly. Install new cylinder head gasket in correct orientation. Carefully lower cylinder head onto block, ensuring dowel pins engage properly. Install NEW cylinder head bolts with light oil on threads. Torque head bolts in proper sequence to 65 Nm (48 lb-ft), then tighten additional 90 degrees in same sequence, followed by final 90 degrees.
    ⚠️Cylinder head bolts are torque-to-yield and must be replaced. Follow tightening sequence exactly as specified in service manual to prevent head gasket failure or head warping.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
19. 19

    Complete engine assembly and reinstall in vehicle
    Complete remaining engine assembly including valve cover, intake manifold, exhaust manifold, and all accessories. Attach engine hoist and carefully remove engine from stand. Lower engine into vehicle engine bay, aligning with transmission and engine mounts. Install transmission-to-engine bolts and torque to 55 Nm (41 lb-ft). Install engine mount bolts per specification. Reconnect all electrical connectors, vacuum lines, coolant hoses, and fuel lines.
    Torque spec

    Transmission-to-Engine Bolts55 Nm (41 lb-ft)
20. 20

    Refill fluids and perform initial startup
    Install new oil filter. Fill engine with 5.0 quarts Toyota Genuine 0W-20 engine oil. Install oil drain plug with new crush washer torqued to 35 Nm (26 lb-ft). Refill cooling system with 10.0 quarts Toyota Super Long Life Coolant (Pink). Reconnect battery. Perform pre-startup checks (verify oil level, coolant level, all connections secure). Crank engine without starting to build oil pressure. Start engine and verify oil pressure immediately. Listen for abnormal noises. Allow engine to reach operating temperature while monitoring for leaks.
    ⚠️If oil pressure warning light does not extinguish within 2-3 seconds of startup, immediately shut off engine and investigate. Running engine without oil pressure will destroy new bearings instantly.
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)

Reassembly

1. All torque-to-yield (TTY) fasteners including main bearing cap bolts, connecting rod bolts, cylinder head bolts, and crankshaft pulley bolt MUST be replaced with new parts
2. All gaskets and seals must be replaced including front and rear main seals, timing cover gasket, oil pan gasket, cylinder head gasket, and valve cover gasket
3. Follow all torque sequences exactly as specified in factory service manual - sequences are critical for even clamping force
4. Use only specified RTV sealant (Toyota FIPG) and apply in continuous bead at specified locations
5. Verify timing chain alignment marks are correct before installing timing cover - incorrect timing will cause valve-to-piston contact
6. Prime oil system before startup if possible by cranking engine with fuel pump fuse removed

Verification

• Verify engine oil pressure rises immediately on startup and oil pressure warning light extinguishes within 2-3 seconds
• Listen for any abnormal mechanical noises including knocking, ticking, or grinding - any abnormal noise requires immediate shutdown and investigation
• Monitor engine for oil, coolant, or fuel leaks during initial warm-up period
• Verify engine idles smoothly and accelerates without hesitation
• Allow engine to reach full operating temperature and verify cooling system operates properly without overheating
• After initial test run, shut down engine and recheck all fluid levels
• After 500-1000 miles, perform oil and filter change to remove any break-in debris
• Monitor oil consumption and engine performance during break-in period (first 1000 miles) - avoid full throttle or sustained high RPM operation during break-in

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