Complete engine removal and reinstallation procedure for the 2019-2024 Toyota RAV4 with 2.5L I4 gasoline engine (FWD). Involves disconnecting all engine systems, separating from transmission, and lifting engine from bay.

Warnings

Tools required

Parts

• Engine oil with filter × 1 — Use OEM specification
• Engine coolant (pink SLLC) × 1 — Use Toyota Super Long Life Coolant
• Oil drain plug crush washer × 1 — 90430-12031
• Lower engine splash shield clips × 1 — As needed
• Exhaust manifold gasket × 1 — Use OEM specification
• Transmission-to-engine gasket/seal × 1 — Use OEM specification
• Engine mount hardware (inspect and replace as needed) × 1 — Various
• Anti-seize compound × 1 — For exhaust fasteners

Fluids

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

Preparation

1. Position vehicle on level surface and engage parking brake
2. Disconnect negative battery cable, then positive cable. Remove battery and battery tray for access
3. Raise vehicle on lift or jack stands at proper jacking points. Vehicle must be stable and secure
4. Remove engine under covers and splash shields
5. Drain engine oil completely and remove oil filter
6. Drain coolant from radiator drain cock and engine block drain plugs into appropriate container
7. Remove hood after marking hinge positions with paint pen for realignment
8. Remove front bumper cover if additional clearance is needed for radiator removal
9. Relieve fuel system pressure by removing fuel pump relay and cranking engine until it stalls

Procedure

1. 1

   Disconnect air intake and throttle systems
   Remove engine air intake duct and air cleaner assembly. Disconnect throttle body electrical connector. Remove engine cover by pulling upward on retaining clips. Disconnect vacuum lines from intake manifold, labeling each for reinstallation.
2. 2

   Remove cooling system components
   Disconnect upper and lower radiator hoses from engine. Disconnect heater hoses at firewall connections. Remove radiator cooling fans (leave attached to radiator). Unbolt and remove radiator assembly toward front of vehicle. Disconnect coolant reservoir hoses.
3. 3

   Disconnect fuel system
   Using fuel line disconnect tools, separate fuel supply and return lines at engine bay connections. Have shop towels ready for residual fuel spillage. Cap open fuel lines to prevent contamination.
   ⚠️Fuel system remains pressurized even after pressure relief. Wear safety glasses and have fire extinguisher nearby.
4. 4

   Remove accessory drive components
   Remove serpentine drive belt by rotating tensioner counterclockwise. Unbolt A/C compressor and secure to frame with wire (do NOT disconnect refrigerant lines unless system has been discharged). Remove alternator and secure wiring. If equipped, remove power steering pump (electric assist on this model, but pump may be present for fluid cooling on hybrid variants - verify configuration).
   Torque spec

   AC Compressor Bolts25 Nm (18 lb-ft)

   Alternator Mounting Bolts50 Nm (37 lb-ft)

   Power Steering Pump Bolts25 Nm (18 lb-ft)
5. 5

   Disconnect exhaust system
   From underneath vehicle, remove oxygen sensor connectors. Unbolt exhaust front pipe from manifold at flange connection. Support exhaust with jack or wire to prevent damage. Remove exhaust manifold heat shields if they interfere with engine removal.
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
6. 6

   Disconnect engine electrical systems
   Disconnect engine wiring harness main connector at firewall (large multi-pin connector). Disconnect remaining electrical connectors including: crankshaft position sensor, camshaft position sensors, knock sensors, oil pressure sensor, coolant temperature sensor, ignition coils, fuel injector harness, and any additional sensors. Remove engine ground straps from block to chassis.
   Torque spec

   Sensor Bolts11 Nm (8 lb-ft)
7. 7

   Disconnect transmission from engine
   Place transmission jack or engine support bar under transmission to support its weight. Remove starter motor and secure aside. Working from underneath, remove all transmission-to-engine bellhousing bolts (typically 6-8 bolts of varying lengths - note locations). Disconnect transmission cooler lines if accessible. Ensure torque converter remains with transmission (for automatic). Carefully separate engine from transmission by pulling engine forward approximately 2-3 inches to clear input shaft.
   ⚠Transmission must be properly supported before removing bellhousing bolts to prevent damage or injury.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)

   Transmission-to-Engine Bolts55 Nm (41 lb-ft)
8. 8

   Remove engine mounts
   Identify all engine mount locations: right side mount, left side mount, front mount, and rear mount. Support engine weight with hoist before removing mount fasteners. Remove engine mount-to-frame bolts first, then engine mount-to-block bolts. Keep hardware organized by location.
   ⚠Engine must be fully supported by hoist before removing any mount bolts. Verify all chains/straps are secure and properly positioned.
   Torque spec

   Engine Mount-to-Block Bolts65 Nm (48 lb-ft)

   Engine Mount-to-Frame Bolts75 Nm (55 lb-ft)
9. 9

   Final disconnections and engine removal
   Perform final inspection to ensure all hoses, wiring, cables, and fasteners are disconnected. Attach engine lifting chain or straps to engine lift points (typically at front and rear of cylinder head). Adjust hoist leveler to keep engine level. Slowly lift engine while guiding it forward and upward to clear transmission input shaft, chassis rails, and firewall. Tilt engine as needed (typically nose-up angle) to clear radiator support. Once clear, lower onto engine stand or secure work surface.
   ⚠️Have assistant guide engine during removal. Watch clearances carefully to avoid damaging vehicle or pinching hands.
10. 10

    Inspect and prepare for reinstallation
    With engine removed, inspect engine mounts for wear or damage and replace if necessary. Inspect transmission input shaft seal and replace if leaking. Clean engine-to-transmission mating surfaces. Inspect flywheel/flexplate for cracks or damage. Replace all gaskets including exhaust manifold gasket. Apply anti-seize to exhaust manifold studs. If replacing rear main seal or doing internal engine work, perform those procedures now.

Reassembly

1. Reinstallation is reverse of removal with these critical notes:
2. Apply thin coat of high-temp grease to transmission input shaft splines before mating engine
3. Ensure torque converter is fully seated in transmission pump (automatic) before mating engine - should be recessed approximately 1/2 inch from bellhousing face
4. Install transmission-to-engine bolts in cross pattern, gradually tightening to pull components together evenly
5. Install engine mounts loosely first, then torque frame bolts followed by block bolts to allow proper alignment
6. Apply anti-seize compound to exhaust manifold studs before installing nuts, tighten in pattern from center outward
7. Double-check that all electrical connectors, hoses, and grounds are reconnected before attempting to start engine
8. Refill engine oil with new filter using specified 0W-20 oil (5.0 quarts)
9. Refill cooling system with Toyota pink SLLC coolant (approximately 10 quarts total capacity)
10. Bleed cooling system by running engine with heater on high until thermostat opens and air purges from system
11. Check transmission fluid level and top off as needed with Toyota WS ATF
12. Reinstall hood using alignment marks made during disassembly

Verification

• With engine installed and all connections made, verify no tools or parts remain in engine bay
• Check that all hose connections are secure with clamps properly tightened
• Verify all electrical connectors are fully seated with locking tabs engaged
• Reconnect battery (positive first, then negative) and check for any stored diagnostic codes
• Prime fuel system by cycling ignition on/off several times without cranking
• Start engine and immediately check for fluid leaks (oil, coolant, fuel) and unusual noises
• Allow engine to reach operating temperature while monitoring coolant level and temperature gauge
• Check all fluid levels again after initial warm-up cycle
• Test drive vehicle and verify normal operation of all engine systems, smooth acceleration, and no warning lights
• Perform final inspection of all fasteners and recheck torque on critical components after test drive
• Clear any diagnostic codes that were set during installation and verify no new codes appear

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