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

Warnings

Tools required

Parts

• Timing chain tensioner assembly × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Crankshaft pulley seal × 1 — Use OEM specification
• Engine oil and filter × 1 — Toyota 04152-YZZA6 or equivalent 0W-20

Fluids

• Toyota Genuine 0W-20 — 5 qt
• Toyota Super Long Life Coolant (Pink) — 1 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Disconnect negative battery terminal and wait 90 seconds for airbag system discharge
3. Remove engine cover by pulling up on front edge, then lifting away
4. Drain engine oil completely and remove oil filter
5. Drain coolant from radiator drain cock until level is below water pump
6. Raise and secure vehicle on jack stands
7. Remove right front wheel and inner fender liner (plastic clips and screws)
8. Support engine with jack and wood block under oil pan or install engine support fixture from above

Procedure

1. 1

   Remove drive belt and accessories
   Rotate drive belt tensioner clockwise using 14mm socket on tensioner bolt and remove drive belt. Remove drive belt tensioner assembly (3 bolts). If necessary for clearance, unbolt power steering pump and set aside without disconnecting lines. Remove alternator if needed for access (electrical connector and mounting bolts).
2. 2

   Remove crankshaft pulley
   Install crankshaft pulley holder tool to prevent rotation. Use breaker bar with 19mm socket to remove crankshaft pulley bolt (counterclockwise). Remove bolt and pulley. Inspect pulley for keyway damage. Clean crankshaft nose and apply small amount of clean engine oil to seal surface.
3. 3

   Remove valve cover
   Disconnect ignition coil connectors and PCV hoses. Remove four ignition coils (10mm bolts). Remove valve cover bolts in reverse of tightening sequence (start from outside, work inward). Carefully lift valve cover away. If stuck, gently tap with rubber mallet. Remove old gasket material and clean mating surfaces thoroughly with brake cleaner and plastic scraper.
4. 4

   Rotate engine to TDC cylinder #1
   Using 19mm socket on crankshaft bolt hole, rotate engine clockwise (viewing from front) until timing marks align: crankshaft timing mark at 12 o'clock position aligns with mark on oil pump body, and camshaft timing marks (stamped circles or dots) on both camshaft sprockets point upward and align with cylinder head surface. Mark all three positions with white paint for reference.
   ⚠Always rotate engine in normal rotation direction (clockwise from front). Never rotate counterclockwise.
5. 5

   Remove timing chain cover
   Remove all timing cover bolts, noting locations as there are different lengths and two different sizes (10mm and 8mm heads). The 8mm bolts are longer and require higher torque. Carefully separate timing cover from block using plastic pry points. Do not pry on sealing surfaces. If cover is stuck, tap gently with soft mallet. Remove cover and old gasket. Clean all mating surfaces with brake cleaner and plastic scraper.
6. 6

   Mark and verify timing alignment
   With timing chain exposed, verify timing marks one final time before proceeding. Mark timing chain links that align with sprocket timing marks using white paint or correction fluid: mark chain link at crankshaft sprocket mark, mark chain links at both camshaft sprocket marks. Take photos for reference. Verify camshaft sprocket bolts are tight.
   ⚠️Do not proceed unless absolutely certain of timing mark alignment. Engine damage will result from incorrect timing.
7. 7

   Remove timing chain tensioner
   Locate timing chain tensioner on right side of engine block. Remove tensioner mounting bolt. Carefully pull tensioner straight out from block. Inspect chain guide (fixed guide on left, pivoting guide on right) for wear or damage. If guides show scoring or wear grooves deeper than 1mm, they should be replaced. Note tensioner orientation for installation.
8. 8

   Prepare new tensioner
   Remove new tensioner from packaging. Using small bench vise or C-clamp, slowly compress tensioner plunger while keeping it straight. Once fully compressed, insert retention pin (supplied with tensioner) or 3mm diameter wire through hole to lock plunger in compressed position. Verify pin is fully seated and plunger cannot extend. Apply small amount of clean engine oil to tensioner body O-ring.
   ℹ️The retention pin must remain in place during installation and will be removed after timing cover is installed.
9. 9

   Install new tensioner and verify timing
   Insert new tensioner (with pin still installed) into engine block bore, ensuring O-ring seats properly. Install tensioner bolt and torque to specification. Do NOT remove retention pin yet. Verify all timing marks still align perfectly with painted chain links. Check chain slack - it should be loose on non-tension side. If timing shifted during tensioner removal, you must realign before proceeding.
10. 10

    Install timing chain cover
    Install new timing cover gasket dry (no RTV needed on gasket itself). Apply thin 2-3mm bead of RTV silicone to cover at oil pan junction points only (two locations where cover meets oil pan). Install cover within 3 minutes of RTV application. Install all timing cover bolts finger-tight first. Torque 10mm head bolts (shorter) to specification, then torque 8mm head bolts (longer) to their specification in sequence from center outward.
    ℹ️RTV requires 24 hours to fully cure, but 1 hour minimum before adding oil.
11. 11

    Release timing chain tensioner
    Locate the small access hole in timing cover that allows access to tensioner pin. Using needle-nose pliers or similar tool, carefully pull retention pin out through access hole. You should feel slight resistance as pin releases. Verify pin is completely removed. The tensioner is now active and applying proper chain tension.
12. 12

    Install crankshaft pulley
    Install new crankshaft seal if removed. Apply thin film of clean engine oil to crankshaft nose and pulley bore. Align pulley keyway with crankshaft key and slide pulley onto crankshaft. Install crankshaft pulley bolt with small amount of clean engine oil on threads. Hold pulley with holder tool and torque bolt to specification. Use torque wrench, not impact gun.
13. 13

    Verify timing by rotation test
    Remove spark plugs to reduce compression resistance. Using socket on crankshaft bolt, slowly rotate engine clockwise through two complete revolutions (720 degrees). Watch timing marks carefully. After two revolutions, all timing marks should return to exact TDC alignment. If marks do not align perfectly, timing installation is incorrect and must be redone.
    ⚠️If timing marks do not realign after two revolutions, DO NOT start engine. Disassemble and correct timing immediately.
14. 14

    Install valve cover and reassemble
    Install new valve cover gasket into cover groove. Apply small dabs of RTV at front camshaft cap corners only. Place valve cover on cylinder head and install bolts finger-tight. Torque valve cover bolts in sequence (start from center, spiral outward) to specification. Reinstall ignition coils with bolts torqued to specification. Connect coil connectors and PCV hoses.
15. 15

    Complete reassembly and refill fluids
    Reinstall alternator and power steering pump if removed. Install drive belt tensioner and drive belt. Reinstall inner fender liner and wheel. Lower vehicle. Install new oil filter and refill engine with 5.0 quarts Toyota 0W-20 oil. Top off coolant to proper level. Reconnect battery negative terminal. Install engine cover.

Reassembly

1. Double-check all fasteners are torqued to specification, particularly timing-related components
2. Verify no tools or rags were left in engine bay
3. Confirm all electrical connectors are properly seated
4. Check that drive belt is properly routed and seated on all pulleys

Verification

• Start engine and verify it starts normally without unusual noise or hesitation
• Listen carefully for timing chain noise - should be quiet with no rattling
• Allow engine to idle for 5 minutes and monitor for oil leaks at timing cover and valve cover
• Check oil level and add if necessary (tensioner may consume small amount)
• Verify no coolant leaks at water pump area of timing cover
• Rev engine to 3000 RPM briefly - timing chain should remain quiet
• Perform test drive and verify normal engine operation under load
• Recheck oil level after test drive when engine is warm
• Inspect timing cover and valve cover for leaks after 24 hours of operation

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