This procedure covers the removal and replacement of the oil pan on a 2019-2024 Toyota RAV4 with the 2.5L I4 gasoline engine, including draining the engine oil, removing the oil pump pickup tube, and installing a new oil pan gasket.

Warnings

Tools required

Parts

• Oil pan gasket × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Toyota 90430-12031
• Engine oil filter × 1 — Use OEM specification
• Oil pump pickup tube O-ring × 1 — Use OEM specification

Fluids

• Toyota Genuine 0W-20 Engine Oil — 5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery terminal and secure cable away from battery post
3. Allow engine to cool completely (minimum 2 hours after operation)
4. Raise vehicle and secure on jack stands at manufacturer-specified lift points
5. Remove front engine splash shield and side covers
6. Install engine support fixture across engine bay or attach lifting chain to engine lift points

Procedure

1. 1

   Drain engine oil
   Place drain pan under oil drain plug. Remove oil drain plug using appropriate socket and allow oil to drain completely (approximately 10-15 minutes). Remove oil filter and allow additional oil to drain from filter mount. Inspect drain plug threads for damage.
   ⚠Hot oil can cause severe burns. Ensure engine is cool before draining.
2. 2

   Remove front exhaust pipe connection
   Disconnect the front exhaust pipe from the exhaust manifold. Remove the two nuts securing the exhaust pipe to the manifold. Support the exhaust pipe and separate it from the manifold. Move exhaust pipe aside for clearance.
3. 3

   Remove engine mount and raise engine
   Remove the right-side engine mount bracket bolts to allow engine movement. Using the engine support fixture, carefully raise the engine approximately 2-3 inches to create clearance between the oil pan and front subframe. Ensure all hoses, wires, and connections have sufficient slack.
   ⚠️Verify engine support is secure and stable before removing mount bolts. Check that no wiring harnesses or hoses are under tension.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
4. 4

   Remove front subframe bolts (if necessary)
   For improved access on some model years, remove or loosen the front subframe mounting bolts and lower the subframe approximately 1-2 inches. Support the subframe with a transmission jack. This step may not be required on all model years but significantly improves access.
5. 5

   Disconnect oil level sensor
   Locate the oil level sensor on the oil pan. Disconnect the electrical connector by pressing the release tab and pulling straight out. Remove the sensor mounting bolt if access is restricted.
   Torque spec

   Sensor Bolts11 Nm (8 lb-ft)
6. 6

   Remove oil pan bolts
   Remove all oil pan mounting bolts in a crisscross pattern, starting from the outer edges and working toward the center. There are approximately 16-18 bolts of varying lengths around the perimeter. Keep track of bolt locations as they may be different lengths. Use extensions and swivel sockets for difficult-to-reach bolts.
7. 7

   Remove oil pump pickup tube
   From inside the oil pan area, locate the oil pump pickup tube mounting bolts (typically 2-3 bolts). Remove these bolts and carefully detach the pickup tube from the oil pump. Support the pickup tube to prevent it from falling.
   Torque spec

   Oil Pump Pickup Tube12 Nm (9 lb-ft)
8. 8

   Remove oil pan
   Carefully pry the oil pan loose from the engine block using a plastic pry tool at designated pry points (small notches in the pan flange). Do not use metal tools that could damage sealing surfaces. Work around the entire perimeter to break the gasket seal. Carefully lower the oil pan, tilting as necessary to clear the pickup tube opening and remove from vehicle.
   ⚠Do not use metal pry bars or screwdrivers on sealing surfaces as this will cause oil leaks. Use only plastic tools at designated pry points.
9. 9

   Clean sealing surfaces
   Thoroughly clean the oil pan and engine block sealing surfaces using a plastic gasket scraper. Remove all old gasket material and RTV sealant. Clean surfaces with brake cleaner and lint-free shop rags. Inspect both surfaces for damage, warping, or cracks. Check oil pan for dents or damage that could affect sealing.
10. 10

    Install oil pump pickup tube
    Install a new O-ring on the oil pump pickup tube. Lubricate the O-ring with clean engine oil. Carefully insert the pickup tube into the oil pump and install mounting bolts. Torque bolts to specification in a crisscross pattern.
    Torque spec

    Oil Pump Pickup Tube12 Nm (9 lb-ft)
11. 11

    Install new oil pan gasket
    Position the new oil pan gasket on the engine block. Ensure all bolt holes align correctly and the gasket is fully seated in the locating features. If using a multi-piece gasket, ensure all sections are properly positioned. Some gaskets may have adhesive backing; ensure it is properly adhered to the block.
12. 12

    Install oil pan
    Carefully lift the oil pan into position, aligning it with the gasket and bolt holes. Start all oil pan bolts by hand to ensure proper thread engagement. Once all bolts are started, tighten them in a crisscross pattern from the center outward to the proper torque specification. Perform final torque in the same sequence.
    ℹ️Follow the tightening sequence to ensure even gasket compression and prevent oil leaks. Over-tightening can warp the oil pan flange.
    Torque spec

    Oil Pan Bolts12 Nm (9 lb-ft)
13. 13

    Reinstall oil level sensor
    If removed, reinstall the oil level sensor with a new O-ring if provided. Torque the sensor bolt to specification. Reconnect the electrical connector until it clicks into place.
    Torque spec

    Sensor Bolts11 Nm (8 lb-ft)
14. 14

    Lower engine and reinstall mounts
    Using the engine support fixture, carefully lower the engine back to its normal position. Reinstall the engine mount bracket and torque all mounting bolts to specification. If subframe was lowered, raise it back to position and torque all subframe bolts to specification.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
15. 15

    Reinstall exhaust and underbody components
    Reconnect the front exhaust pipe to the exhaust manifold with new gaskets. Torque nuts to specification. Install a new oil filter and hand-tighten. Install oil drain plug with new crush washer and torque to specification. Reinstall all splash shields and underbody covers.
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)
16. 16

    Fill with engine oil and check for leaks
    Lower vehicle from jack stands. Remove engine support fixture. Fill engine with 5.0 quarts of Toyota Genuine 0W-20 engine oil. Reconnect negative battery terminal. Start engine and allow to idle for 2-3 minutes while monitoring oil pressure warning light (should extinguish within seconds). Check for leaks around oil pan, drain plug, and oil filter. Shut off engine, wait 5 minutes, and recheck oil level on dipstick. Add oil if necessary to bring to full mark.

Reassembly

1. Ensure all bolts are torqued to specification in proper sequence
2. Verify all electrical connectors are fully seated and locked
3. Double-check that engine support fixture is removed before starting engine
4. Verify subframe and motor mount bolts are properly torqued if they were removed or loosened

Verification

• Start engine and verify oil pressure warning light extinguishes within 3-5 seconds
• Allow engine to reach operating temperature and inspect for leaks around entire oil pan perimeter
• Check oil level after engine has been running and cooled for 5 minutes; oil should be at full mark on dipstick
• Test drive vehicle and recheck for leaks after 10-20 miles of operation
• Inspect oil pan area after 24 hours and again after 100 miles for any seepage

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