engine

Oil Pump

for 2021 Toyota RAV4 2.5L I4 · AWD

Difficulty

Expert

Time

6.3 h

Tools

Steps

This procedure covers removal and replacement of the oil pump on a 2019-2024 Toyota RAV4 with the 2.5L I4 engine, requiring engine support, timing chain cover removal, and precise timing chain alignment.

Warnings

⚠️Engine must be fully supported from above before removing motor mounts. Failure to properly support engine can result in engine dropping and causing serious injury or death.

⚠Timing chain alignment is critical. Incorrect installation will result in severe engine damage upon startup. Verify all timing marks are aligned before reassembly.

⚠Do not rotate crankshaft or camshafts independently once timing chain is removed. This will cause valve-to-piston contact and engine damage.

ℹ️This procedure requires engine support and partial disassembly of the timing system. Consider whether oil pump replacement is necessary versus diagnosing the actual failure.

Tools required

Engine support fixture or hoistEssential

Torque wrench (10-50 Nm range)Essential

Socket set (8mm-19mm)

Timing chain alignment tool setEssential

Oil filter wrench

Oil drain pan (6+ quart capacity)Essential

Engine coolant drain panEssential

Razor blade scraper

RTV sealant application gunEssential

Pry bar

Jack and jack standsEssential

Engine hoist or support barEssential

Parts

Oil pump assembly × 1 — Use OEM specification
Timing chain cover gasket × 1 — Use OEM specification
Oil pan gasket × 1 — Use OEM specification
Oil pump pickup tube O-ring × 1 — Use OEM specification
Oil drain plug crush washer × 1 — 90430-12031
Oil filter × 1 — Use OEM specification
Front crankshaft seal × 1 — Use OEM specification
RTV silicone sealant × 1 — Toyota Genuine or equivalent

Fluids

Toyota Genuine 0W-20 engine oil — 5 qt
Toyota Super Long Life Coolant (Pink) — 3 qt

Preparation

Ensure engine is completely cold before beginning work
Disconnect negative battery cable and secure away from terminal
Raise and safely support vehicle on jack stands at manufacturer lift points
Remove engine undercover and front splash shields
Install engine support fixture from above or prepare engine hoist with load leveler
Place drain pans under engine for oil and coolant collection

Procedure

1
Drain fluids and remove accessories
Remove oil drain plug with new crush washer ready for reinstallation. Drain engine oil completely. Remove oil filter. Drain engine coolant from radiator drain cock and lower radiator hose. Remove drive belts by releasing tensioner. Remove alternator and set aside with wiring attached.
Torque spec
Oil Drain Plug35 Nm (26 lb-ft)
2
Remove right engine mount
Support engine weight with engine support fixture from above, ensuring engine is stable and secure. Remove right-side engine mount bracket and through-bolt. The engine will need to be raised slightly after mount removal to provide clearance for timing cover removal.
⚠️Verify engine is fully supported before removing any mount bolts. Engine must not shift or drop during this procedure.
Torque spec
Mounting Bolts27 Nm (20 lb-ft)
3
Remove crankshaft pulley and water pump
Lock crankshaft using appropriate holding tool. Remove crankshaft pulley center bolt (requires breaker bar, typically 200+ Nm). Remove crankshaft pulley using harmonic balancer puller. Remove water pump assembly from timing cover (4 bolts). Disconnect water pump hoses and set pump aside.
Torque spec
Mounting Bolts27 Nm (20 lb-ft)
4
Remove timing chain cover
Remove all timing chain cover bolts in reverse of tightening sequence (approximately 19 bolts of varying lengths - note locations). Carefully separate timing cover from engine block using plastic pry points. Do not damage sealing surfaces. Remove and discard timing cover gasket.
⚠Track bolt locations carefully as timing cover uses different length bolts in specific positions. Improper bolt installation can cause cover damage or oil leaks.
Torque spec
Cover Bolts16 Nm (12 lb-ft)
5
Verify and mark timing chain alignment
Rotate crankshaft to TDC on cylinder #1 (compression stroke). Verify timing marks on camshaft sprockets align with marks on timing chain and that crankshaft keyway is at 12 o'clock position. Mark timing chain relationship to all sprockets with paint marker. Photograph timing marks for reference.
⚠️Accurate timing mark documentation is critical. Take multiple clear photographs from different angles showing all timing mark relationships before proceeding.
6
Remove timing chain tensioner and guides
Remove timing chain tensioner by pushing in plunger and installing retaining pin, then remove mounting bolts. Remove timing chain guide bolts and guides. The timing chain can now be carefully lifted off the sprockets while maintaining alignment marks. Support chain to prevent it from falling into engine.
Torque spec
Mounting Bolts27 Nm (20 lb-ft)
7
Remove oil pan
Remove all oil pan bolts in crisscross pattern starting from outer edges working inward. Carefully separate oil pan from block using plastic pry tool at designated pry points. Remove and discard oil pan gasket. Clean all gasket material from oil pan and engine block mating surfaces using razor blade scraper. Surfaces must be completely clean and dry.
Torque spec
Oil Pan Bolts12 Nm (9 lb-ft)
8
Remove oil pump pickup tube
Remove two bolts securing oil pump pickup tube to oil pump and engine block. Remove pickup tube and O-ring. Inspect pickup screen for debris or damage - clean or replace as necessary.
Torque spec
Oil Pump Pickup Tube12 Nm (9 lb-ft)
9
Remove oil pump assembly
Remove oil pump mounting bolts (typically 3 bolts). Carefully work oil pump assembly away from engine block and crankshaft. The inner rotor is engaged with the crankshaft and may require gentle rotation while pulling to disengage. Remove and discard oil pump O-ring and gasket.
Torque spec
Oil Pump Bolts12 Nm (9 lb-ft)
10
Inspect and prepare for installation
Inspect crankshaft oil pump drive for wear or damage. Clean oil pump mounting surface on engine block thoroughly. Verify new oil pump rotates freely by hand. Lubricate new oil pump O-ring with clean engine oil. Align oil pump inner rotor with crankshaft flats before installation.
ℹ️Oil pump inner rotor must engage with crankshaft properly. Forcing the pump onto misaligned crankshaft will damage pump or crankshaft.
11
Install new oil pump
Install new O-ring on oil pump. Carefully align oil pump inner rotor with crankshaft drive flats. Slide oil pump onto crankshaft while rotating slightly to ensure engagement. Once seated flush against block, install oil pump bolts finger tight, then torque in crisscross pattern to specification.
Torque spec
Oil Pump Bolts12 Nm (9 lb-ft)
12
Install oil pump pickup tube and oil pan
Install new O-ring on oil pump pickup tube. Install pickup tube and torque bolts to specification. Install new oil pan gasket or apply RTV sealant per manufacturer specification (if RTV type, install within 3 minutes of application). Install oil pan and torque bolts in crisscross pattern from center outward.
Torque spec
Oil Pump Pickup Tube12 Nm (9 lb-ft)
Oil Pan Bolts12 Nm (9 lb-ft)
13
Reinstall timing chain and components
Carefully reinstall timing chain onto sprockets, aligning all timing marks exactly as photographed during removal. Verify crankshaft is still at TDC and camshaft marks align. Install timing chain guides and tensioner. Remove tensioner retaining pin to apply tension. Rotate crankshaft two complete revolutions and verify all timing marks realign perfectly.
⚠️Timing marks must align perfectly after rotating crankshaft two full turns. If marks do not realign, DO NOT start engine. Remove timing cover and verify chain installation.
Torque spec
Mounting Bolts27 Nm (20 lb-ft)
14
Install timing chain cover
Clean timing cover mating surfaces thoroughly. Install new timing cover gasket or apply RTV sealant per manufacturer specification. Install timing cover and all bolts finger tight. Tighten timing cover bolts in specified sequence to 25 Nm. Install new front crankshaft seal if needed.
Torque spec
Cover Bolts16 Nm (12 lb-ft)
15
Reinstall external components
Reinstall water pump with new gasket and torque bolts to specification. Install crankshaft pulley and torque center bolt to specification (typically 200+ Nm). Reinstall alternator and torque mounting bolts. Reinstall right engine mount and torque all fasteners. Remove engine support fixture. Install drive belts. Install engine undercovers.
Torque spec
Mounting Bolts27 Nm (20 lb-ft)

Reassembly

Install new oil drain plug crush washer and torque drain plug to 35 Nm
Install new oil filter and fill engine with 5 quarts of Toyota Genuine 0W-20 oil
Refill cooling system with Toyota Super Long Life Coolant (Pink) - approximately 3 quarts needed to replace lost coolant
Reconnect negative battery cable
Double-check all fasteners are tightened to specification
Verify no tools or parts are left in engine compartment

Verification

Start engine and verify oil pressure warning light extinguishes within 2-3 seconds
Allow engine to idle and inspect for oil leaks around oil pan, timing cover, and oil pump area
Monitor oil pressure gauge (if equipped) for normal pressure readings: 4.1 psi minimum at idle, 36-78 psi at 3000 RPM
Verify no coolant leaks from water pump or timing cover area
Check engine for abnormal noises indicating timing issues - engine should run smoothly
After engine reaches operating temperature, shut off and recheck oil level, top off if needed
Test drive vehicle and verify normal operation with no warning lights
Recheck all fluid levels and inspect for leaks after test drive