This procedure covers the replacement of the timing chain guide on the 2019-2024 Toyota RAV4 2.5L I4 engine, requiring removal of the timing cover and precise alignment of timing marks.

Warnings

Tools required

Parts

• Timing chain guide × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Crankshaft front oil seal × 1 — Use OEM specification
• Engine oil × 1 — Toyota Genuine 0W-20
• Engine coolant × 1 — Toyota Super Long Life Pink

Fluids

• Toyota Genuine 0W-20 — 5 qt
• Toyota Super Long Life Coolant (Pink) — 2 qt

Preparation

1. Ensure engine is completely cold. Park vehicle on level surface and engage parking brake.
2. Disconnect negative battery terminal and wait 90 seconds for airbag system to discharge.
3. Remove engine cover by pulling upward on clip fasteners.
4. Drain engine coolant into appropriate container by opening radiator petcock and lower radiator hose.
5. Drain engine oil completely and remove oil filter.
6. Remove right front wheel and inner fender liner for access to crankshaft pulley.
7. Support engine from above using engine support fixture or from below with jack and wood block under oil pan.
8. Mark and photograph all timing marks on camshaft sprockets and crankshaft before any disassembly.

Procedure

1. 1

   Remove accessory drive belt and components
   Rotate the tensioner clockwise to release tension and remove the accessory drive belt. Remove the alternator mounting bolts and set alternator aside without disconnecting wiring. Remove the A/C compressor mounting bolts and secure compressor to frame without disconnecting refrigerant lines.
2. 2

   Remove right engine mount
   With engine properly supported, remove the right engine mount bracket bolts. Remove the engine mount through-bolt and remove the mount assembly completely. This provides clearance for timing cover removal.
   ⚠Ensure engine is securely supported before removing mount. Engine will shift during removal.
3. 3

   Remove crankshaft pulley
   Install crankshaft holding tool to prevent rotation. Use breaker bar to loosen crankshaft pulley bolt (counterclockwise). Remove bolt completely and pull crankshaft pulley off using appropriate puller if necessary. Mark pulley orientation for reinstallation.
   ⚠Crankshaft pulley bolt is extremely tight. Ensure holding tool is secure to prevent engine rotation damage.
   Torque spec

   Crankshaft pulley bolt193 Nm (142 lb-ft)
4. 4

   Remove valve cover
   Disconnect ignition coil connectors and PCV hoses. Remove ignition coils. Remove valve cover bolts in reverse of tightening sequence (outside to inside pattern). Carefully lift valve cover and remove gasket. Clean all gasket surfaces thoroughly.
5. 5

   Rotate engine to TDC compression stroke cylinder 1
   Rotate crankshaft clockwise using socket on crankshaft nose until timing marks align: crankshaft keyway at 12 o'clock, camshaft timing marks aligned with head surface marks. Verify both intake and exhaust cam lobes for cylinder 1 are pointing upward (valve overlap position). This is critical for timing chain removal.
   ⚠️Always rotate engine in normal direction of rotation (clockwise from front). Never rotate backwards.
6. 6

   Remove timing cover
   Remove all timing cover bolts noting their different lengths and positions. There are multiple bolt sizes - 8mm bolts require different torque than standard bolts. Gently pry timing cover away from block using plastic wedge at designated pry points. Remove timing cover and gasket completely. Do not damage sealing surfaces.
7. 7

   Verify and mark timing chain position
   With timing cover removed, verify all timing marks are still aligned. Use paint marker or scribe to mark chain position on both camshaft sprockets and crankshaft sprocket. Mark chain links directly adjacent to sprocket timing marks. Photograph chain routing around all guides and tensioner for reference.
   ⚠️This is your last opportunity to verify timing before disassembly. Misalignment here will cause engine damage.
8. 8

   Remove timing chain tensioner
   Remove the timing chain tensioner bolt and carefully extract the tensioner assembly. The tensioner is spring-loaded - control it during removal. Inspect tensioner for wear or damage and replace if necessary even if not originally planned.
9. 9

   Remove camshaft sprocket bolts
   Hold each camshaft sprocket using appropriate holding tool to prevent rotation. Remove both camshaft sprocket bolts. Do not allow camshafts to rotate during this process. Leave sprockets loosely in place on camshafts for now.
   ⚠Camshaft sprocket bolts may have thread locker applied. Heat may be required for removal.
10. 10

    Remove timing chain and inspect guides
    Carefully remove both camshaft sprockets with chain still engaged. Lift timing chain off crankshaft sprocket. Remove chain completely from engine. Inspect all guide bolts and remove the worn timing chain guide by removing its mounting bolts. Inspect the guide for wear grooves, cracks, or material breakdown.
    Torque spec

    Chain guide bolts9 Nm (80 lb-ft)
11. 11

    Install new timing chain guide
    Clean mounting surfaces thoroughly with brake cleaner. Position new timing chain guide in place and install mounting bolts finger-tight. Torque timing chain guide bolts to specification in a cross pattern. If guide has multiple bolts, use the appropriate torque value for each size. Verify guide is secure and properly seated.
    Torque spec

    Chain guide bolts9 Nm (80 lb-ft)
12. 12

    Install timing chain and sprockets
    Verify crankshaft is still at TDC (keyway at 12 o'clock). Install timing chain on crankshaft sprocket first. Route chain around new guide following photographed routing. Install camshaft sprockets with chain engaged, aligning timing marks with marked chain links. Verify all timing marks align perfectly before proceeding. Install camshaft sprocket bolts finger-tight.
    ⚠️Timing marks must align exactly. One tooth off will cause valve-to-piston contact and engine destruction.
13. 13

    Torque camshaft sprockets and install tensioner
    Hold camshaft sprockets with holding tool and torque sprocket bolts to specification. Install timing chain tensioner with new bolt and torque to specification. Release tensioner mechanism to apply proper chain tension. Manually rotate crankshaft two complete revolutions clockwise and verify timing marks realign at TDC. If marks do not realign perfectly, disassemble and correct.
    ⚠️If timing marks do not realign after two rotations, do NOT proceed. Disassemble and find error.
14. 14

    Install timing cover with new gasket
    Clean all timing cover and block mating surfaces completely with gasket scraper. Remove all old gasket material and RTV. Apply thin bead of Toyota Genuine RTV silicone to timing cover in designated areas per service manual. Install new timing cover gasket. Position timing cover carefully and install all bolts finger-tight. Torque timing cover bolts in proper sequence: start with center bolts and work outward. Use correct torque for 8mm bolts versus standard bolts.
    ℹ️Do not over-apply RTV. Excess sealant can break off and clog oil passages.
15. 15

    Install crankshaft pulley and valve cover
    Install new crankshaft front seal if removed. Align crankshaft pulley with keyway and slide into place. Install crankshaft pulley bolt and torque to specification using holding tool. Install new valve cover gasket. Apply small dab of RTV at camshaft cap corners. Install valve cover and torque bolts in sequence (inside to outside pattern). Reinstall ignition coils and reconnect all electrical connections.
    Torque spec

    Crankshaft pulley bolt193 Nm (142 lb-ft)

Reassembly

1. Reinstall right engine mount and torque all fasteners to specification.
2. Reinstall A/C compressor and alternator with all mounting bolts properly torqued.
3. Install accessory drive belt following proper routing diagram on belt routing decal.
4. Reinstall inner fender liner and right front wheel. Torque lug nuts to specification.
5. Reinstall engine cover by pressing down on clip locations until seated.
6. Allow RTV sealant to cure for minimum 2 hours before filling fluids.

Verification

• Fill engine with 5.0 quarts of Toyota Genuine 0W-20 engine oil and install new oil filter.
• Refill cooling system with Toyota Super Long Life Pink coolant. Bleed air from system using bleeder screw on thermostat housing.
• Reconnect negative battery terminal.
• Start engine and verify no unusual noises. Listen carefully for timing chain rattle or tensioner noise.
• Allow engine to reach operating temperature and check for oil or coolant leaks around timing cover and valve cover.
• Verify engine idles smoothly with no misfires or rough running.
• Clear any diagnostic trouble codes that may have set during battery disconnect.
• Perform test drive and verify normal engine performance and no warning lights.

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