This procedure covers the removal and replacement of the harmonic balancer (crankshaft pulley) on the 2019-2024 Toyota RAV4 with the 2.5L I4 gasoline engine, including accessory belt removal and crankshaft bolt service.

Warnings

Tools required

Parts

• Harmonic balancer/crankshaft pulley × 1 — Use OEM specification
• Crankshaft pulley bolt (if TTY) × 1 — Use OEM specification - verify if reusable

Preparation

1. Park vehicle on level surface and apply parking brake. Place wheel chocks behind rear wheels.
2. Disconnect negative battery terminal and wait 5 minutes for system discharge.
3. Raise and secure front of vehicle on jack stands rated for vehicle weight.
4. Remove right front wheel to access engine splash shield area.
5. Remove engine splash shield and right-side engine undercover for access to crankshaft pulley area.
6. Verify you have the correct harmonic balancer for your specific 2.5L A25A-FKS engine variant.

Procedure

1. 1

   Remove accessory drive belt
   Locate the drive belt tensioner on the right side of the engine. Using a 14mm socket and breaker bar, rotate the tensioner clockwise to relieve tension. Slip the belt off the pulleys and carefully release the tensioner. Remove the belt from the engine bay. Note the belt routing before removal or photograph for reference.
2. 2

   Position vehicle for crankshaft bolt access
   Ensure the vehicle is stable on jack stands. Position yourself under the front of the vehicle with adequate lighting. The crankshaft pulley is located at the bottom front of the engine, centered on the crankshaft.
3. 3

   Prevent crankshaft rotation
   Have an assistant apply the brake pedal firmly, or place the transmission in Park (automatic) with parking brake engaged. Alternatively, use a crankshaft holding tool or strap wrench on the harmonic balancer to prevent rotation. Some technicians use a starter bump method, but this requires experience.
   ⚠Do not use an air impact wrench for removal without proper crankshaft restraint, as this can damage internal engine components.
4. 4

   Remove crankshaft pulley bolt
   Using a 19mm socket with breaker bar or impact wrench, remove the crankshaft pulley bolt by turning counterclockwise. This bolt is torqued to 180 Nm and will require significant force. If using a breaker bar, a sharp initial force is often more effective than steady pressure. Remove the bolt and washer completely.
   ⚠Inspect the bolt threads and washer seat. If the bolt is TTY (torque-to-yield), it must be replaced per Toyota specifications.
   Torque spec

   Harmonic Balancer Bolt180 Nm (133 lb-ft)
5. 5

   Install harmonic balancer puller
   Thread the harmonic balancer puller bolts into the threaded holes in the pulley face. Ensure the puller is centered and the forcing screw contacts the crankshaft snout center. Do not allow the forcing screw to contact threads or damaged surfaces.
6. 6

   Remove harmonic balancer
   Gradually tighten the puller forcing screw while maintaining even pressure. The balancer will slowly separate from the crankshaft. Continue until the balancer is completely free. Remove the puller and balancer together, then separate them on the bench.
   ⚠If the balancer does not move after reasonable force, stop and verify puller alignment. Excessive force may indicate a seized balancer requiring heat or penetrating oil.
7. 7

   Inspect crankshaft and balancer
   Clean the crankshaft snout with a lint-free cloth. Inspect for burrs, scoring, or damage. Check the keyway for damage or wear. Inspect the harmonic balancer hub bore and keyway for wear, cracks, or rubber deterioration (if rubber-isolated type). Replace if any damage is found.
8. 8

   Prepare new harmonic balancer
   Apply a thin coat of clean engine oil to the crankshaft snout and the inner bore of the new harmonic balancer. Align the keyway in the balancer with the key on the crankshaft. Do not use anti-seize on the crankshaft snout itself.
9. 9

   Install new harmonic balancer
   Carefully slide the harmonic balancer onto the crankshaft, ensuring the keyway engages properly. Push it on by hand as far as possible. The balancer should slide on smoothly without binding. Do not hammer the balancer onto the crankshaft.
   ⚠The balancer must be drawn on using the crankshaft bolt only. Never use an installation driver that contacts the outer ring on rubber-isolated balancers.
10. 10

    Install and torque crankshaft bolt
    Install the crankshaft bolt (new if TTY) with its washer. Hand-thread the bolt to ensure proper thread engagement. Using the same crankshaft holding method as removal, torque the bolt to 180 Nm (133 lb-ft) using a calibrated torque wrench. If the bolt is TTY and manufacturer specifies an additional angle, apply the specified angle rotation after reaching initial torque.
    ⚠Verify with Toyota service manual if additional angle torque is required beyond the 180 Nm specification for your model year.
    Torque spec

    Harmonic Balancer Bolt180 Nm (133 lb-ft)
11. 11

    Reinstall accessory drive belt
    Route the accessory drive belt around all pulleys according to the routing diagram (on the belt routing sticker under the hood or your reference photo). Rotate the tensioner clockwise and slip the belt over the final pulley. Release the tensioner to apply proper tension. Verify the belt is seated correctly in all pulley grooves.
12. 12

    Reinstall undercovers and wheel
    Reinstall the right-side engine undercover and engine splash shield, securing all fasteners. Install the right front wheel and torque lug nuts to specification (typically 110 Nm but verify for your specific wheel type). Lower the vehicle to the ground.

Reassembly

1. Reconnect the negative battery terminal and tighten securely.
2. Double-check that all fasteners have been reinstalled and torqued properly.
3. Verify accessory drive belt is properly seated and tensioned before starting engine.

Verification

• Start the engine and listen for any unusual noises from the crankshaft pulley area.
• Observe the harmonic balancer while engine is running at idle - it should rotate smoothly without wobble or vibration.
• Check for any belt squealing or slipping during initial startup and while revving engine slightly.
• Shut off engine and visually inspect the crankshaft bolt area for proper seating and no visible gaps between balancer and crankshaft.
• Test drive the vehicle and verify no abnormal vibrations at various engine speeds.
• After 50-100 miles of operation, re-verify crankshaft bolt torque to ensure it has not loosened.

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