This procedure covers removal and replacement of the front crankshaft oil seal (front main seal) on the 2019-2024 Toyota RAV4 with 2.5L I4 engine, requiring removal of accessory drive components and timing cover.

Warnings

Tools required

Parts

• Front crankshaft oil seal × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Toyota Genuine FIPG sealant (or equivalent) × 1 — Toyota Part 08826-00080

Fluids

• Toyota Genuine 0W-20 — 5 qt
• Toyota Super Long Life Coolant (Pink) — 2 qt

Preparation

1. Ensure engine is completely cool to the touch
2. Disconnect negative battery cable and isolate
3. Raise vehicle on lift or support securely on jack stands at manufacturer lift points
4. Remove engine under covers and splash shields
5. Install engine support fixture across engine bay to support engine weight
6. Place oil drain pan under vehicle

Procedure

1. 1

   Drain engine oil and coolant
   Remove oil drain plug and drain engine oil completely into pan. Remove radiator drain plug or lower coolant hose and drain approximately 2 quarts of coolant into separate container (enough to drop level below water pump). Install drain plug with new crush washer.
   Torque spec

   Oil Drain Plug35 Nm (26 lb-ft)
2. 2

   Remove accessory drive belt and components
   Rotate belt tensioner clockwise to release tension and remove accessory drive belt. Remove belt from all pulleys and note routing for reinstallation. If necessary, take photo of belt routing before removal.
3. 3

   Remove right engine mount
   Support engine with support fixture from above. Remove right side engine mount bolts (mounting to frame and engine bracket). Remove or loosen mount assembly to gain access to crankshaft pulley area.
   Torque spec

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

   Remove crankshaft pulley
   Install crankshaft holding tool to prevent rotation. Remove crankshaft pulley bolt using breaker bar or impact wrench (bolt is torqued to 133 lb-ft). Note: This is often a torque-to-yield bolt - if replacing per service manual, use new bolt. Remove harmonic balancer/pulley from crankshaft using appropriate puller if necessary. Do not pry against timing cover.
   ⚠Crankshaft must be held securely during bolt removal. Do not use starter motor method on this engine.
   Torque spec

   Crankshaft Pulley Bolt180 Nm (133 lb-ft)
5. 5

   Remove timing cover bolts
   Remove all timing cover bolts. There are multiple bolt sizes: 10mm head bolts and 8mm head bolts at various locations around perimeter of cover. Note bolt locations as different length bolts are used in different positions. The cover extends down to the front section of the oil pan.
   Torque spec

   Cover Bolts16 Nm (12 lb-ft)
6. 6

   Separate and remove timing cover
   Carefully separate timing cover from engine block. Use plastic scraper to break RTV seal if necessary - do not pry with metal tools against sealing surfaces. The cover may also be sealed to the front of the oil pan. Remove cover completely, taking care not to damage timing chain or guides behind it. Keep cover flat to prevent warping.
7. 7

   Remove front crankshaft seal
   Using seal puller or pick tools, carefully extract the old front crankshaft seal from the timing cover bore. Work around the perimeter of seal to pull it out evenly. Take care not to damage the seal bore in the cover. Clean the seal bore thoroughly with brake cleaner and inspect for any damage or scratches that could cause new seal to leak.
   ⚠Do not score or scratch the seal bore surface. Any damage to bore will cause new seal to leak.
8. 8

   Clean all sealing surfaces
   Using plastic scrapers and brake cleaner, remove all old RTV sealant and gasket material from timing cover mating surface and engine block face. Also clean the front section of oil pan where timing cover mates. Surfaces must be completely clean and dry for proper seal. Inspect crankshaft seal surface (snout) for any grooves or damage - minor imperfections can be smoothed with fine emery cloth.
9. 9

   Install new front crankshaft seal
   Lightly oil the outer diameter of new seal and the seal bore. Position new seal squarely in timing cover bore with seal lip facing inward (toward engine). Using appropriately sized seal driver or socket that contacts only the outer edge of seal, carefully drive seal into bore until it is fully seated and flush with cover surface. Apply thin coat of clean engine oil to seal lip.
   ⚠Drive seal in squarely and evenly. Driving at an angle will damage seal and cause immediate leak.
10. 10

    Apply sealant and position timing cover gasket
    Install new timing cover gasket on engine block, ensuring all bolt holes align. Apply continuous bead (3-4mm diameter) of Toyota FIPG sealant or equivalent to the joints where timing cover meets the oil pan, and at the cylinder head-to-block corner joints. Sealant must be applied to both the block and the cover in these areas per Toyota specifications.
    ℹ️Timing cover must be installed within 3 minutes of sealant application before it begins to cure.
11. 11

    Install timing cover
    Carefully position timing cover onto engine block, ensuring gasket stays in position and crankshaft enters the new seal squarely without binding. Install all timing cover bolts finger-tight, ensuring correct bolts are in correct locations. Tighten bolts in sequence (center outward pattern) - first 8mm bolts to 18 lb-ft, then 10mm bolts to 33 lb-ft. If cover includes oil pan bolts at bottom, tighten those to 9 lb-ft.
    ⚠Bolt tightening sequence must be followed to ensure even cover seating and prevent leaks.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)

    Oil Pan Bolts12 Nm (9 lb-ft)
12. 12

    Install crankshaft pulley
    Clean crankshaft snout and inner bore of pulley/harmonic balancer. Apply small amount of clean engine oil to crankshaft seal contact area. Slide pulley onto crankshaft, ensuring it seats fully against inner timing gear or spacer. Install crankshaft bolt (use new bolt if specified as TTY). Hold crankshaft and torque bolt to 133 lb-ft. An impact wrench may be required for final torque.
    Torque spec

    Harmonic Balancer Bolt180 Nm (133 lb-ft)
13. 13

    Reinstall engine mount and accessories
    Reinstall right engine mount assembly and torque mounting bolts to specification (20 lb-ft for frame mount, 35 lb-ft for engine bracket mount depending on location). Remove engine support fixture. Reinstall accessory drive belt following noted routing diagram.
    Torque spec

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

    Refill fluids
    Refill engine with 5.0 quarts of Toyota Genuine 0W-20 engine oil. Refill cooling system with Toyota Super Long Life Coolant (pink) to proper level. Bleed cooling system if necessary by running engine to operating temperature with heater on.

Reassembly

1. Reinstall all engine covers and splash shields
2. Reconnect negative battery cable
3. Double-check all fasteners are tightened to specification
4. Verify no tools or rags left in engine bay

Verification

• Start engine and verify no oil leaks from timing cover or crankshaft seal area
• Allow engine to reach operating temperature and recheck for leaks with oil at full pressure
• Check engine oil level after initial run and top off if necessary
• Verify coolant level is correct and system has no air locks
• Listen for any abnormal noises from timing cover area during engine operation
• Inspect repair area after test drive and overnight cold soak for any signs of seepage

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