Complete long block replacement procedure for 2019-2024 Toyota RAV4 2.5L I4, including removal and installation of engine assembly with all associated systems and components.

Warnings

Tools required

Parts

• Long block assembly (2.5L A25A-FKS engine) × 1 — Use OEM specification
• Engine oil filter × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — 90430-12031
• Valve cover gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Exhaust manifold gasket × 1 — Use OEM specification
• Intake manifold gasket × 1 — Use OEM specification
• Water pump gasket/O-ring × 1 — Use OEM specification
• Thermostat gasket × 1 — Use OEM specification
• Front crankshaft seal × 1 — Use OEM specification
• Rear main seal × 1 — Use OEM specification
• Engine coolant × 1 — Toyota Super Long Life Coolant
• Engine mount set (front, rear, right) × 1 — Use OEM specification
• Spark plugs (if reusing accessories) × 4 — 90919-01253

Fluids

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

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and secure away from terminal
3. Remove engine cover and air intake assembly
4. Drain engine coolant completely from radiator and block drain plugs
5. Drain engine oil and remove oil filter
6. Remove front bumper cover for radiator access
7. Remove radiator, condenser, and cooling fans as assembly
8. Recover A/C refrigerant using proper equipment if A/C lines must be disconnected
9. Raise and secure vehicle on jack stands at all four corners
10. Remove front wheels and engine splash shields
11. Label and photograph all electrical connectors, vacuum lines, and hose routing before removal

Procedure

1. 1

   Disconnect engine electrical and fuel systems
   Relieve fuel system pressure by removing fuel pump relay and cranking engine. Disconnect fuel lines at fuel rail using disconnect tool. Remove engine wiring harness from all sensors including oxygen sensors, VVT solenoids, cam/crank sensors, injector connectors, and ignition coils. Disconnect throttle body connector and all accessory wiring. Remove engine ground straps from block to chassis.
2. 2

   Remove intake and exhaust systems
   Remove throttle body and intake manifold assembly. Disconnect exhaust downpipe from exhaust manifold at flange. Remove exhaust manifold from cylinder head. Clean all mounting surfaces thoroughly.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
3. 3

   Remove accessory drive components
   Remove serpentine belt. Remove alternator with mounting bracket. Remove A/C compressor and secure to frame without disconnecting lines if possible. Remove power steering pump if equipped (this vehicle has EPS, no pump). Remove all accessory brackets from engine block.
4. 4

   Disconnect cooling system components
   Disconnect upper and lower radiator hoses, heater hoses, and bypass hoses from engine. Remove thermostat housing. Disconnect coolant temperature sensors. Cap all open coolant passages to prevent debris entry.
5. 5

   Remove valve cover and timing components
   Remove ignition coils and spark plugs. Remove valve cover. Rotate crankshaft to TDC on cylinder #1 and verify timing marks alignment. Remove timing chain tensioner. Remove timing chain guide and timing chain. Remove camshaft sprockets using holding tool. Remove VVT solenoids and oil control valves.
   Torque spec

   Cover Bolts16 Nm (12 lb-ft)

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

   Camshaft Cap Bolts14 Nm (10 lb-ft)
6. 6

   Support and separate transmission
   Support transmission with transmission jack. Remove starter motor. Remove all transmission-to-engine bolts noting different lengths. Carefully separate transmission from engine, ensuring torque converter remains with transmission. Support transmission securely and do not allow to hang on axles.
   Torque spec

   Transmission-to-Engine Bolts55 Nm (41 lb-ft)
7. 7

   Remove engine mounts and extract engine
   Attach engine hoist with load leveler to engine lifting eyes. Take up slack and support engine weight. Remove right engine mount, front engine mount, and rear engine mount. Verify all connections are disconnected. Slowly raise engine while tilting as needed to clear transmission input shaft, checking clearances continuously. Lift engine out of vehicle and place on engine stand.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
8. 8

   Transfer reusable components from old block
   Remove all reusable components from old engine: oil pan, timing cover, water pump, oil pump, flywheel/flexplate, cylinder head (if not included with long block), sensors, switches, and all external accessories. Inspect all components for wear and replace as needed. Clean all mounting surfaces thoroughly with brake cleaner.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)

   Cover Bolts16 Nm (12 lb-ft)

   Flywheel Bolts95 Nm (70 lb-ft)
9. 9

   Install components on new long block
   Install rear main seal on new block. Install flywheel/flexplate with new bolts, torquing in star pattern. Install oil pump with new gasket. Install oil pan with new gasket or RTV as specified. Install timing cover with new gasket. Install water pump with new gasket. Install all sensors with new O-rings where applicable. Apply threadlocker to sensor bolts.
   Torque spec

   Flywheel Bolts95 Nm (70 lb-ft)

   Oil Pan Bolts12 Nm (9 lb-ft)

   Cover Bolts16 Nm (12 lb-ft)

   Sensor Bolts11 Nm (8 lb-ft)
10. 10

    Install cylinder head and valve train
    If cylinder head was removed, install on new block with new head gasket ensuring proper orientation. Install cylinder head bolts following TTY procedure: torque to 65 Nm in sequence, then additional 90 degrees, then final 90 degrees. Install camshafts with timing marks aligned. Install camshaft caps in sequence from center outward in multiple passes to 14 Nm. Install timing chain with marks aligned, chain guides, and tensioner.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)

    Camshaft Cap Bolts14 Nm (10 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
11. 11

    Install engine into vehicle
    Attach engine to hoist and position above engine bay. Guide engine down slowly, aligning with transmission input shaft and engine mount locations. Install and hand-tighten all engine mount bolts. Align engine to transmission and install all transmission-to-engine bolts to specification. Torque engine mount bolts in sequence.
    Torque spec

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

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

    Reconnect accessories and exhaust
    Install starter motor. Reinstall all accessory brackets and components (alternator, A/C compressor). Install serpentine belt. Install exhaust manifold with new gasket, applying anti-seize to studs and torquing nuts from center outward. Connect exhaust downpipe. Install intake manifold with new gasket.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)

    Intake Manifold Bolts25 Nm (18 lb-ft)
13. 13

    Install valve cover and ignition components
    Install new valve cover gasket. Install valve cover and torque bolts in sequence from center outward to 10 Nm. Install spark plugs and ignition coils. Connect all ignition coil connectors.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)
14. 14

    Reconnect all systems
    Reconnect all engine wiring harness connectors using labels from disassembly. Install ground straps. Reconnect fuel lines ensuring proper seating. Connect all coolant hoses. Connect all vacuum lines. Double-check all connections against photographs taken during disassembly.
15. 15

    Fill fluids and perform initial start
    Install new oil filter. Fill engine with 5 quarts of Toyota Genuine 0W-20 oil. Fill cooling system with Toyota Super Long Life Coolant, bleeding air from system using bleeder valves. Reconnect battery. Perform initial start and monitor for leaks, unusual noises, or warning lights. Allow engine to reach operating temperature and verify proper operation of cooling fans and thermostat. Check and adjust fluid levels as needed.
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)

Reassembly

1. Reinstall radiator, condenser, and cooling fan assembly
2. Install front bumper cover
3. Install engine splash shields and front wheels
4. Lower vehicle and torque wheel lug nuts to specification
5. Install air intake assembly and engine cover
6. Perform complete visual inspection of engine bay for any disconnected items

Verification

• Start engine and verify no oil or coolant leaks from all gasket surfaces and connections
• Verify engine runs smoothly with no misfires or abnormal noises
• Check that all warning lights extinguish after start
• Verify cooling system maintains proper temperature with no overheating
• Test drive vehicle to verify normal operation under load
• Recheck all fluid levels after test drive and top off as needed
• Scan for diagnostic trouble codes and verify none present
• Verify proper operation of all accessories (alternator charging, A/C function, etc.)
• Recheck engine mount bolt torque after initial operation
• Schedule follow-up oil and filter change at 500 miles for break-in period

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