This procedure covers the complete replacement of main bearings on a 2019-2024 Toyota RAV4 2.5L I4 engine, requiring engine removal from the vehicle and complete disassembly of the lower end.

Warnings

Tools required

Parts

• Main bearing set (standard or appropriate oversize) × 1 — Use OEM specification
• Thrust bearing set × 1 — Use OEM specification
• Main cap bolts (TTY - must replace) × 10 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Oil pump seal/gasket × 1 — Use OEM specification
• Rear main seal × 1 — Use OEM specification
• Front crankshaft seal × 1 — Use OEM specification
• Timing chain cover gasket × 1 — Use OEM specification
• Oil filter × 1 — Use OEM specification
• Engine coolant drain plug seal × 1 — Use OEM specification
• RTV silicone gasket maker (Toyota FIPG) × 1 — Use OEM specification

Fluids

• Toyota Genuine 0W-20 Engine Oil — 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 terminal and secure cable away from battery
3. Drain engine coolant completely into suitable container
4. Drain engine oil and remove oil filter
5. Remove engine cover and air intake assembly
6. Relieve fuel system pressure by removing fuel pump relay and cranking engine briefly
7. Mark and photograph all electrical connectors, vacuum lines, and hose routing for reassembly reference
8. Remove hood and front bumper cover for access
9. Raise and support vehicle securely on jack stands
10. Remove front wheels and splash shields

Procedure

1. 1

   Remove engine from vehicle
   Disconnect all electrical connectors from engine harness. Disconnect fuel lines, coolant hoses, heater hoses, and vacuum lines. Remove radiator and cooling fans. Disconnect exhaust pipe from manifold. Remove drive belts and accessories (alternator, A/C compressor - support without disconnecting refrigerant lines). Unbolt engine mounts and transmission bell housing. Attach engine hoist with chains positioned at factory lift points. Support transmission with jack. Carefully lift engine while monitoring for any remaining connections. Once clear, transfer engine to engine stand.
2. 2

   Strip engine for lower end access
   With engine on stand, remove timing chain cover, timing chain, and camshafts (mark all components for reassembly position). Remove cylinder head (will need new head gasket upon reassembly). Remove oil pan carefully, noting any RTV application points. Remove oil pickup tube and windage tray if equipped. Remove oil pump assembly. Clean all mating surfaces thoroughly.
3. 3

   Mark and inspect main caps
   Before removal, verify main bearing caps are numbered 1-5 from front to back. Note the directional arrows or markings on caps (they face forward). Check for any existing bearing identification marks. Inspect cap bolts for any damage or stretching. Take photographs showing cap orientation and position.
4. 4

   Remove main bearing caps
   Working from the outer caps toward center (caps 1, 5, 2, 4, then 3), loosen main cap bolts gradually in multiple passes to avoid crankshaft distortion. Remove bolts completely and carefully lift each cap straight up, keeping caps in order. Do not pry on caps. If cap is stuck, tap gently with soft mallet on sides only. Remove lower bearing shells from caps and keep with corresponding cap.
5. 5

   Remove crankshaft and upper bearings
   Carefully lift crankshaft straight up out of block. This requires two people or a lifting strap due to weight (approximately 50-60 lbs). Place crankshaft on clean, padded work surface. Remove upper bearing shells from block, noting which position each came from. Inspect thrust bearing location (typically center main #3).
6. 6

   Inspect and measure crankshaft journals
   Clean all crankshaft main journals thoroughly with solvent and lint-free cloth. Inspect for scoring, discoloration, or damage. Using micrometer, measure each journal diameter at multiple points (minimum 4 points per journal, checking for taper and out-of-round). Standard journal diameter is approximately 48mm (verify with service manual). Out-of-round should not exceed 0.01mm. Record all measurements. If journals are worn beyond 0.25mm, crankshaft requires grinding and oversize bearings.
7. 7

   Inspect and measure bearing bores
   Clean all bearing bores in block and caps thoroughly. Inspect for damage, scoring, or cracks. Using telescoping bore gauge and micrometer, measure each bearing bore in block. Check for out-of-round and taper. Bearing bore should be within 0.02mm of specification (approximately 52mm standard). If bores are damaged or out-of-spec beyond tolerance, block requires line boring or replacement.
8. 8

   Install new bearings and check clearances with Plastigage
   Clean all bearing surfaces with clean, lint-free cloth (no solvent on new bearings). Install upper bearing shells in block, ensuring locating tabs engage slots properly. Bearings should snap into place firmly. Place strips of Plastigage across each crankshaft journal parallel to crankshaft centerline. Carefully lower crankshaft into block without rotating. Install lower bearings in caps. Install caps in correct positions with arrows facing forward. Install NEW main cap bolts finger tight only. Torque caps to 40 Nm (30 lb-ft) ONLY - do not apply angle yet. Do not rotate crankshaft.
   Torque spec

   Main Cap Bolts75 Nm (55 lb-ft) + 90°
9. 9

   Measure bearing clearances
   Remove main caps one at a time in reverse order of installation (do not disturb crankshaft). Measure width of crushed Plastigage using scale on package. Standard clearance should be 0.02-0.04mm (0.0008-0.0016 inches). If clearance is too tight (less than 0.02mm), verify correct bearing size and journal measurements. If too loose (more than 0.04mm), use next undersize bearing or determine if crankshaft requires grinding. Remove all Plastigage material completely with clean cloth.
10. 10

    Final main bearing installation
    Apply thin coat of assembly lube or fresh engine oil to all bearing surfaces. Install upper bearings in block. Carefully install crankshaft. Install lower bearings in caps with thin coat of assembly lube. Verify thrust bearing is correctly positioned at center main. Install caps in order with arrows facing forward, ensuring perfect alignment. Install NEW main cap bolts and torque in sequence from center outward (3, 2, 4, 1, 5) to 40 Nm (30 lb-ft). Then apply additional 90-degree angle to each bolt in same sequence using angle gauge.
    Torque spec

    Main Cap Bolts75 Nm (55 lb-ft) + 90°
11. 11

    Check crankshaft endplay and rotation
    Using dial indicator or feeler gauge, check crankshaft endplay (thrust clearance) by prying crankshaft fully forward and backward. Standard endplay is 0.03-0.18mm. If excessive, verify thrust bearing installation. Rotate crankshaft by hand through at least two complete revolutions. Rotation should be smooth with no binding or tight spots. Any resistance indicates misalignment or incorrect assembly - disassemble and inspect immediately.
12. 12

    Install oil pump and pickup tube
    Install new front crankshaft seal in timing cover. Install oil pump assembly with new gasket or seal. Install oil pickup tube with new O-ring or gasket. Install windage tray if equipped. Verify all fasteners are torqued to specification per service manual.
13. 13

    Install oil pan
    Clean oil pan and block mating surfaces thoroughly. Apply continuous bead of Toyota FIPG RTV sealant to oil pan flange per service manual specifications (typically 3-4mm bead). Install oil pan within 3 minutes of applying RTV. Install oil pan bolts and torque to 16 Nm (12 lb-ft) in crisscross pattern from center outward. Allow RTV to cure for minimum 2 hours before adding oil.
    Torque spec

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

    Reassemble engine upper end
    Install new rear main seal using seal installation tool. Install cylinder head with new head gasket, following proper torque sequence and specifications. Install camshafts in original positions, verifying timing marks. Install timing chain with marks properly aligned. Install timing chain cover with new gasket and proper RTV application. Install all accessories, sensors, and external components removed during disassembly.
15. 15

    Install engine and complete assembly
    Carefully lower engine back into vehicle using hoist. Align engine mounts and install mounting bolts. Reconnect transmission bell housing. Reconnect all electrical connectors, fuel lines, coolant hoses, vacuum lines, and exhaust. Install all accessories and drive belts. Install radiator and cooling system components. Fill with fresh Toyota 0W-20 oil and new oil filter. Fill cooling system with Toyota Super Long Life Coolant. Reinstall all splash shields, wheels, bumper cover, and hood.

Reassembly

1. Double-check all main cap orientations before final torque - arrows must face forward
2. Use only NEW main cap bolts - never reuse torque-to-yield fasteners
3. Allow RTV sealant to cure for minimum 2 hours before filling with oil
4. Verify crankshaft rotates freely by hand before installing cylinder head
5. Follow cylinder head torque sequence exactly per service manual specifications
6. Ensure timing marks are perfectly aligned before starting engine

Verification

• Verify all fluid levels are correct (oil, coolant) before starting
• Start engine and check for oil pressure within 5 seconds - should reach 30+ psi at idle when warm
• Monitor for any unusual noises, knocking, or vibration during initial start and warm-up
• Check for oil leaks around oil pan, timing cover, and all gasket surfaces
• Allow engine to reach operating temperature and verify no overheating
• Road test vehicle under light load initially, gradually increasing load over first 500 miles
• Change oil and filter after 500 miles of break-in period
• Monitor oil pressure and consumption during break-in period - verify readings remain normal

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