This procedure covers the removal and reinstallation of the cylinder head on a 2019-2024 Toyota RAV4 with the 2.5L I4 gasoline engine, including timing chain removal, head bolt replacement, and gasket replacement.

Warnings

Tools required

Parts

• Cylinder head gasket × 1 — Use OEM specification
• Cylinder head bolts (set of 10) × 1 — 90910-02236
• Valve cover gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Exhaust manifold gasket × 1 — Use OEM specification
• Intake manifold gasket × 1 — Use OEM specification
• Oil filter × 1 — Use OEM specification
• Spark plugs (set of 4) × 1 — 90919-01253
• Engine coolant × 1 — Toyota Super Long Life Coolant

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 since last operation)
2. Disconnect negative battery cable and wait 90 seconds for airbag system discharge
3. Raise vehicle and support securely on jack stands
4. Remove engine under covers and splash shields
5. Drain engine coolant completely into suitable container
6. Drain engine oil and remove oil filter
7. Remove front bumper cover for access to cooling system components
8. Position engine support fixture across engine bay to support engine weight

Procedure

1. 1

   Remove intake and exhaust systems
   Remove air intake assembly from air filter box to throttle body. Disconnect all vacuum lines, PCV hoses, and electrical connectors from intake manifold. Remove intake manifold bolts and set aside manifold with fuel injectors attached. Disconnect exhaust manifold from exhaust pipe. Remove heat shields and disconnect oxygen sensors. Remove exhaust manifold mounting bolts and separate manifold from cylinder head.
   ⚠Label all electrical connectors and vacuum lines during removal to ensure correct reassembly
2. 2

   Remove valve cover and accessory components
   Disconnect ignition coils and remove all four coils from spark plug wells. Disconnect PCV valve and ventilation hoses from valve cover. Remove valve cover bolts in reverse of tightening sequence (outside to inside). Carefully lift valve cover and remove gasket. Remove accessory drive belt and tensioner. Remove alternator and set aside with wiring attached.
   Torque spec

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

   Position engine to TDC and mark timing components
   Rotate crankshaft clockwise using 19mm socket on crankshaft pulley bolt until number 1 cylinder is at top dead center (TDC) on compression stroke. Verify timing marks on camshaft gears align with marks on timing cover. Mark timing chain position on both camshaft gears using paint marker. Mark chain link positions relative to timing marks. This is critical for reassembly timing.
   ⚠️Precise timing mark documentation is essential. Take photos of all timing marks and chain positions before proceeding
4. 4

   Remove timing components
   Support engine from below and remove right side engine mount. Remove crankshaft pulley bolt (requires holding crankshaft from rotation). Remove timing chain cover bolts and carefully separate cover from block. Install timing chain holding tool to prevent chain from falling into engine. Remove camshaft timing gear bolts while using camshaft holding tool. Remove timing chain tensioner and guide. Carefully remove timing chain from camshaft gears while keeping it supported on crankshaft gear.
   ⚠Do not allow timing chain to drop into lower engine. Use holding tool or wire to secure chain position
   Torque spec

   Cover Bolts16 Nm (12 lb-ft)
5. 5

   Disconnect remaining cylinder head components
   Disconnect all remaining electrical connectors including camshaft position sensors, VVT solenoids, and coolant temperature sensors. Disconnect fuel supply line from fuel rail (depressurize fuel system first by removing fuel pump relay and cranking engine). Disconnect coolant hoses from cylinder head including heater hoses and coolant bypass. Cap all open coolant passages and fuel lines.
   ⚠️Fuel system must be depressurized before disconnecting fuel lines. Residual pressure can spray fuel causing fire hazard
   Torque spec

   Sensor Bolts11 Nm (8 lb-ft)
6. 6

   Remove cylinder head bolts
   Remove cylinder head bolts in reverse of tightening sequence (from outside toward center, in three passes). Loosen each bolt gradually in 1/4 turn increments to prevent head warping. Once all bolts are loose, remove them completely. Inspect bolts and confirm they will be replaced with new torque-to-yield bolts. Keep bolts organized to verify count (should be 10 bolts total).
   ⚠Use proper loosening sequence to prevent cylinder head warping. Never remove bolts in random order
7. 7

   Remove cylinder head
   With all bolts removed, carefully break cylinder head seal from block using plastic pry points (do not pry on sealing surfaces). Lift cylinder head straight up evenly to prevent damage to dowel pins. Place cylinder head on clean wooden blocks with combustion chambers facing up. Remove and discard old cylinder head gasket from engine block. Inspect head surface and block surface for damage, warping, or debris.
   ⚠Never pry between head and block sealing surfaces. Use only designated pry points or head will be damaged
8. 8

   Clean and inspect mating surfaces
   Using plastic gasket scraper, carefully clean all gasket material from cylinder head mating surface and engine block surface. Do not use metal scrapers that can gouge aluminum surfaces. Clean oil and coolant passages with solvent and compressed air. Inspect cylinder head for cracks, especially around valve seats and combustion chambers. Check head surface flatness with precision straightedge (maximum warpage tolerance is 0.05mm). Inspect block surface similarly.
9. 9

   Install new cylinder head gasket and position head
   Verify engine block surface is completely clean and dry. Install new cylinder head gasket onto block, ensuring all alignment dowels pass through gasket holes correctly. Verify gasket orientation (TOP or FRONT marks facing up). Carefully lower cylinder head onto block, aligning with dowel pins. Ensure head seats completely flat against gasket before installing bolts.
   ⚠Head gasket must be installed in correct orientation. Verify TOP marking and coolant passage alignment before proceeding
10. 10

    Install and torque cylinder head bolts
    Install all 10 new cylinder head bolts hand-tight in their original positions. Using torque wrench, tighten all bolts to 36 Nm (27 lb-ft) in proper sequence (center outward in spiral pattern). Then, using angle gauge, rotate each bolt an additional 90 degrees in same sequence. Finally, rotate each bolt another 90 degrees in same sequence (total of 180 degrees additional rotation after initial torque). Verify all bolts have been properly torqued and angled.
    ⚠️Cylinder head bolt torque sequence and angle procedure must be followed exactly. Incorrect procedure will cause head gasket failure
    Torque spec

    Cylinder Head Bolts36 Nm (27 lb-ft) + 180°
11. 11

    Reinstall timing components
    Position timing chain onto crankshaft gear. Rotate camshafts to align with timing marks documented during disassembly. Install timing chain onto camshaft gears while aligning painted chain links with gear timing marks. Install camshaft gear bolts and torque to specification using camshaft holding tool. Install timing chain tensioner and guide. Rotate crankshaft two complete revolutions and verify all timing marks realign correctly at TDC.
    ⚠️After installing timing components, manually rotate engine through two complete revolutions to verify proper timing and ensure no valve-to-piston interference before starting engine
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
12. 12

    Install timing cover and valve cover
    Clean timing cover mating surfaces and install new timing cover gasket. Position timing cover and install all bolts, torquing to 16 Nm (12 lb-ft) in crisscross pattern. Install crankshaft pulley and torque center bolt to specification. Clean valve cover and head mating surfaces. Install new valve cover gasket and position valve cover on head. Install cover bolts and torque to 16 Nm (12 lb-ft) working from center outward.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)
13. 13

    Reconnect all components and systems
    Install new spark plugs and torque to specification. Reinstall ignition coils. Reconnect all electrical connectors including sensors, solenoids, and ignition coils. Reconnect fuel supply line with new O-rings. Reconnect all coolant hoses and clamps. Install exhaust manifold with new gasket and torque mounting bolts to specification. Install intake manifold with new gasket and torque bolts to specification. Reinstall alternator, drive belt, and tensioner. Reinstall engine mount.
    ℹ️Replace all gaskets and O-rings during reassembly. Reusing old gaskets will cause leaks
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)

    Gasket Bolts20 Nm (15 lb-ft)
14. 14

    Refill fluids and prepare for startup
    Reinstall engine under covers and splash shields. Lower vehicle from jack stands. Install new oil filter and refill engine with 5.0 quarts Toyota Genuine 0W-20 engine oil. Refill cooling system with Toyota Super Long Life Coolant (Pink) mixture - approximately 10 quarts total. Bleed cooling system by running engine with radiator cap off until thermostat opens and coolant circulates. Reconnect negative battery cable.

Reassembly

1. Double-check all electrical connectors are fully seated and locked
2. Verify all coolant hoses are properly clamped and secured
3. Confirm all intake and exhaust fasteners are torqued to specification
4. Check that no tools or parts remain in engine bay before starting
5. Verify oil level is correct on dipstick after filling

Verification

• Start engine and listen for unusual noises, particularly valve train noise that would indicate timing issues
• Check for coolant leaks around cylinder head, timing cover, and hose connections while engine warms up
• Check for oil leaks around valve cover and timing cover
• Verify no fuel leaks at fuel rail connections
• Monitor engine temperature gauge for normal operating temperature and proper thermostat operation
• Check for exhaust leaks at manifold connection
• After engine reaches operating temperature, verify cooling fans cycle properly
• Perform test drive and verify normal engine performance, smooth acceleration, and no check engine light
• After test drive, recheck coolant level when engine is cold and top off if necessary
• Recheck oil level after engine has sat for 10 minutes and top off if needed

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