This procedure covers removal, machining, and reinstallation of the cylinder head on the 2019-2024 Toyota RAV4 2.5L I4 engine to correct warping or surface damage.

Warnings

Tools required

Parts

• Cylinder head gasket × 1 — Use OEM specification
• Cylinder head bolt set (TTY) × 1 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Exhaust manifold gasket × 1 — Use OEM specification
• Intake manifold gasket × 1 — Use OEM specification
• Timing chain cover gasket × 1 — Use OEM specification
• Spark plugs × 4 — Use OEM specification
• VVT-i sprocket bolt × 2 — Use OEM specification
• Engine oil filter × 1 — Use OEM specification

Fluids

• Toyota Genuine 0W-20 — 5 qt
• Toyota Super Long Life Coolant (Pink) — 10 qt

Preparation

1. Ensure engine is completely cold (minimum 4 hours after last operation)
2. Disconnect negative battery terminal and wait 90 seconds for airbag system discharge
3. Relieve fuel system pressure by removing fuel pump relay and cranking engine until it stops
4. Drain engine coolant completely into appropriate container
5. Drain engine oil and remove oil filter
6. Remove engine cover and plastic undertray
7. Support engine from above using hoist with load leveler or install engine support fixture across fender wells
8. Label all electrical connectors, vacuum lines, and coolant hoses with tape for reassembly reference

Procedure

1. 1

   Remove Intake and Exhaust Systems
   Disconnect air intake tube from throttle body. Remove intake manifold by disconnecting all vacuum lines, PCV hoses, and electrical connectors. Unbolt intake manifold and remove. Disconnect exhaust manifold from catalytic converter. Remove exhaust manifold heat shields and unbolt exhaust manifold from cylinder head.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
2. 2

   Remove Valve Cover and Ignition Components
   Disconnect ignition coil connectors and remove all four ignition coils. Remove spark plugs and store safely. Disconnect PCV hose and breather hose from valve cover. Remove valve cover bolts in reverse of tightening sequence and carefully remove valve cover and gasket.
   Torque spec

   Cover Bolts16 Nm (12 lb-ft)
3. 3

   Remove Accessory Drive Components
   Remove serpentine belt by releasing tensioner. Remove alternator and set aside with wiring attached. Remove A/C compressor mounting bolts and secure compressor aside without disconnecting refrigerant lines. Remove power steering pump if applicable and secure aside.
   Torque spec

   Mounting Bolts47 Nm (35 lb-ft)
4. 4

   Remove Timing Chain Cover
   Remove crankshaft pulley using holding tool and breaker bar. Remove all timing chain cover bolts including the bolts accessible from underneath. Carefully separate timing chain cover from engine block and cylinder head. Clean all gasket material from mating surfaces.
   Torque spec

   Cover Bolts16 Nm (12 lb-ft)

   Gasket Bolts20 Nm (15 lb-ft)
5. 5

   Lock Timing Chain and Remove Camshaft Components
   Rotate crankshaft to TDC cylinder #1 (timing marks aligned). Install timing chain holding tool to prevent chain movement. Mark camshaft sprocket and chain relationship with paint pen. Remove VVT-i sprocket bolts while holding camshafts with holding tool. Carefully remove both camshaft sprockets keeping timing chain supported.
6. 6

   Remove Camshaft Bearing Caps and Camshafts
   Loosen camshaft bearing cap bolts in multiple passes working from outside toward center to release valve spring tension evenly. Remove bearing caps keeping them in order and noting directional arrows. Carefully lift out intake and exhaust camshafts. Store camshafts on clean surface to prevent damage to journals and lobes.
7. 7

   Remove Cylinder Head
   Disconnect all remaining sensors from cylinder head (coolant temperature, knock sensor, oil pressure sender). Loosen cylinder head bolts in reverse of tightening sequence in multiple passes to prevent warping. Remove all cylinder head bolts and set aside (these will be replaced). Carefully lift cylinder head straight up from engine block using assistance if needed. Place cylinder head on clean wooden blocks with combustion chambers facing up.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
8. 8

   Inspect and Measure Cylinder Head
   Remove all carbon deposits from combustion chambers using approved cleaner. Clean cylinder head gasket surface with plastic scraper (never metal). Using straightedge and feeler gauges, measure cylinder head flatness at multiple points longitudinally and diagonally. Check across intake and exhaust sides. Record all measurements. If warpage is 0.05-0.20mm, head can be resurfaced. If over 0.20mm, head must be replaced.
9. 9

   Machine Shop Resurfacing
   Transport cylinder head to qualified machine shop for resurfacing. Specify Toyota maximum material removal limits. Have shop verify valve seat concentricity and valve stem heights after resurfacing. Request pressure test to verify no cracks exist. Have machine shop clean head thoroughly after machining including all oil passages.
10. 10

    Prepare Engine Block and Install New Head Gasket
    Clean engine block deck surface thoroughly with plastic scraper removing all old gasket material. Vacuum out cylinders and oil passages. Verify block deck is clean and dry with no oil residue. Check cylinder bores for damage or scoring. Install new cylinder head gasket on block with proper orientation (TOP mark facing up). Align gasket dowel pins. Do not use any sealant on head gasket.
11. 11

    Install Cylinder Head
    Carefully lower cylinder head onto engine block ensuring gasket stays properly aligned with dowel pins. Install NEW cylinder head bolts (TTY bolts cannot be reused) with light oil on threads. Hand-tighten all bolts in sequence. Using torque wrench, tighten all bolts to 65 Nm (48 lb-ft) in proper sequence. Then tighten each bolt an additional 90 degrees using angle gauge in same sequence. Finally tighten each bolt another 90 degrees (total 180 degrees additional) in sequence.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
12. 12

    Install Camshafts and Timing Components
    Lubricate camshaft journals and lobes with clean engine oil. Install camshafts in proper positions (intake and exhaust marked). Install bearing caps in correct positions following directional arrows. Tighten bearing cap bolts in multiple passes from center outward. Install camshaft sprockets aligning timing marks made during disassembly. Install new VVT-i sprocket bolts and torque while holding camshafts. Verify all timing marks align at TDC before removing holding tool.
13. 13

    Install Timing Chain Cover and Accessories
    Install new timing chain cover gasket. Apply small bead of Toyota Genuine Seal Packing to specified areas per service manual. Install timing chain cover and tighten bolts in sequence. Install crankshaft pulley and torque to specification. Reinstall alternator, A/C compressor, and power steering pump. Install serpentine belt ensuring proper routing.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)

    Gasket Bolts20 Nm (15 lb-ft)

    Mounting Bolts47 Nm (35 lb-ft)
14. 14

    Install Valve Cover and Manifolds
    Install new valve cover gasket in valve cover groove. Apply small amount of sealant at camshaft cap corners. Install valve cover and tighten bolts in sequence to specification. Install new exhaust manifold gasket with proper orientation. Install exhaust manifold and apply anti-seize to stud threads. Tighten nuts in sequence from hot side to cold side. Install new intake manifold gasket and install intake manifold. Tighten bolts to specification.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)

    Exhaust Manifold Nuts30 Nm (22 lb-ft)

    Intake Manifold Bolts25 Nm (18 lb-ft)
15. 15

    Final Reassembly and Fill Fluids
    Install new spark plugs and torque to specification. Install ignition coils and connect all electrical connectors. Reconnect all vacuum lines, coolant hoses, and sensors per labeling from disassembly. Install new engine oil filter. Fill engine with 5.0 quarts Toyota Genuine 0W-20 oil. Fill cooling system with 10.0 quarts Toyota Super Long Life Coolant mixture. Reconnect exhaust system. Reconnect battery. Double-check all connections before starting.
    Torque spec

    Sensor Bolts11 Nm (8 lb-ft)

Reassembly

1. Verify all torque specifications were followed and torque-to-yield procedure completed correctly
2. Ensure timing chain holding tool was removed before attempting to start engine
3. Verify all electrical connectors are fully seated and locked
4. Check that no tools or rags remain in engine compartment

Verification

• Start engine and listen for abnormal noises (knocking, ticking, or timing-related sounds)
• Allow engine to reach operating temperature while monitoring for coolant or oil leaks at cylinder head gasket, valve cover, and timing cover
• Verify no coolant loss and check for proper thermostat operation
• Check for smooth idle and proper throttle response
• After 20 minutes of operation, shut off engine and recheck all fluid levels when cool
• Perform test drive monitoring for hesitation, misfires, or overheating
• Recheck all external bolts for proper torque after engine cools
• Monitor for leaks and engine performance over next 100 miles; retorque cylinder head bolts is NOT required with TTY bolts

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