Cylinder Head Installation

Place a new gasket on the cylinder block surface with the Lot No. stamp facing upward.

NOTICE:

1. Remove any oil from contact surface.
   

1. Be careful of the installation direction.
   

Place the cylinder head on the head gasket.

NOTICE:

Place the cylinder head gently in order to avoid damaging the gasket.

Install the cylinder head bolts.

NOTICE:

The cylinder head bolts are tightened in 2 successive steps.

1. Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.
   

2. Using several steps, uniformly install and tighten the 10 cylinder head set bolts and plate washers with a 10 mm bi-hexagon wrench in the order shown in the illustration.
   

   Torque:

   78.5 N*m{800 kgf*cm, 58 ft.*lbf}

Mark the front of the cylinder head bolts with paint.

Retighten the cylinder head bolts by 90° as shown in the illustration.

Check that the paint mark is now at a 90° angle to the front.

Put the camshaft timing gear and camshaft together with the straight pin and key groove misaligned, as shown in the illustration.

Turn the camshaft timing gear as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.

NOTICE:

Be sure not to turn the camshaft timing gear to the retard angle side (the right angle).

Check that there is no clearance between the gear fringe and camshaft.

Tighten the flange bolt with the camshaft timing gear fixed in place.

Torque:

54 N*m{551 kgf*cm, 40 ft.*lbf}

Check that the camshaft timing gear can move to the retard angle side (the right direction) and is locked in the most retarded position.

Clamp the camshaft in a vise, then install the camshaft timing sprocket with the bolt.

Torque:

54 N*m{551 kgf*cm, 40 ft.*lbf}

NOTICE:

Do not damage the camshaft.

Apply a light coat of engine oil to the journal portion of the camshaft.

Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing the directions shown in the illustration.

Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head.

Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

Using several steps, uniformly tighten the 20 bearing cap bolts in the sequence shown in the illustration.

Torque:

29.5 N*m{301 kgf*cm, 22 ft.*lbf} for No. 1 and No. 2 bearing cap

9.0 N*m{92 kgf*cm, 80 in.*lbf} for No. 3 bearing cap

NOTICE:

1. Tighten the bolts after deciding the position in the thrust direction of the camshaft by the No. 1 and No. 2 bearing caps.
   
2. Install the camshaft with the timing mark of the camshaft timing gear on top.
   

Install the chain vibration damper with the 2 bolts.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Set the No. 1 cylinder to TDC/compression.

1. Turn the camshafts with a wrench (using the hexagonal lobe) to align the timing marks of the camshaft timing gear with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration.
   





2. Using the crankshaft pulley bolt, turn the crankshaft to position the key on the crankshaft upward.
   

Install the chain onto the crankshaft timing sprocket with the gold or orange mark link aligned with the timing mark on the crankshaft.

Using SST and a hammer, tap in the crankshaft timing sprocket.

SST

09309-37010

Align the gold or yellow links with each timing mark located on the camshaft timing gear and sprocket, then install the chain.

Install the chain tensioner slipper with the bolt.

Torque:

19 N*m{194 kgf*cm, 14 ft.*lbf}

Install the timing chain guide with the bolt.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Install the sensor plate with the "F" mark facing forward.

Remove any old packing material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.

Apply seal packing (Diameter 4.0 to 4.5 mm (0.157 to 0.177 in.)) as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent

NOTICE:

1. Remove any oil from the contact surface.
   

1. Install the chain cover within 3 minutes of applying seal packing.
   

1. Do not add engine oil for at least 2 hours after installing the chain cover.
   

Apply a continuous bead of seal packing as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent

NOTICE:

1. Remove any oil from the contact surface.
   

1. Install the chain cover within 3 minutes of applying seal packing.
   

1. Do not add engine oil for at least 2 hours after installing the chain cover.
   
   
   
   
   
   

Install the timing chain cover with the 11 bolts and 2 nuts.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf} for bolt A

25 N*m{255 kgf*cm, 18 ft.*lbf} for bolt B

55 N*m{561 kgf*cm, 41 ft.*lbf} for bolt C

11 N*m{112 kgf*cm, 8 ft.*lbf} for nut

HINT:

Bolt length:

Using an E10 "torx" socket, install the stud bolt for the V-ribbed belt tensioner.

Torque:

21.5 N*m{219 kgf*cm, 16 ft.*lbf}

Release the ratchet pawl, then fully push in the plunger and hook the hook to the pin so that the plunger is in the position shown in the illustration.

Install a new gasket and the chain tensioner with the 2 nuts.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

NOTICE:

When installing the chain tensioner, set the hook again if the hook releases the plunger.

Install the V-ribbed belt tensioner with the bolt and nut.

Torque:

59.5 N*m{607 kgf*cm, 44 ft.*lbf}

NOTICE:

Do not lift the engine more than necessary.

Install the engine mounting bracket RH with the 3 bolts.

Torque:

55 N*m{561 kgf*cm, 41 ft.*lbf}

Using SST, fix the pulley in place and tighten the bolt.

SST

09213-54015(91651-60855)
09330-00021

Torque:

180 N*m{1,835 kgf*cm, 133 ft.*lbf}

Turn the crankshaft counterclockwise, then disconnect the plunger knock pin from the hook.

Turn the crankshaft clockwise, then check that the plunger is extended.

Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.

Apply a continuous bead of seal packing (Diameter 3.0 to 4.0 mm (0.118 to 0.157 in.)) as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent

NOTICE:

1. Remove any oil from the contact surface.
   

1. Install the oil pan within 3 minutes of applying seal packing.
   

1. Do not add engine oil for at least 2 hours after installing the oil pan.
   

Install the oil pan to the cylinder block.

Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Place a transmission jack underneath the engine, then put a wooden block on the jack.

Remove the chain block and sling device.

Remove the No. 1 and No. 2 engine hangers.

Apply a light coat of engine oil to the O-ring of the sensor.

Install the sensor with the bolt.

Torque:

9.0 N*m{90 kgf*cm, 80 in.*lbf}

Install the wire harness clamp.

Install the connector clamp.

Connect the sensor connector.

Confirm that the wire harness of the sensor is secured to the wire harness clamp bracket through the back of the rib of the timing chain cover.

Remove any old packing material from the contact surface.

Apply seal packing to the 2 locations shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent

NOTICE:

1. Remove any oil from the contact surface.
   

1. Install the oil pan within 3 minutes of applying seal packing.
   

1. Do not add engine oil for at least 2 hours after installing the oil pan.
   

Install the cylinder head cover with the 8 bolts and 2 nuts.

Torque:

11 N*m{112 kgf*cm, 8 ft.*lbf} for bolt A

14 N*m{143 kgf*cm, 10 ft.*lbf} for bolt B

11 N*m{112 kgf*cm, 8 ft.*lbf} for nut

Install the 2 engine wires with the 2 bolts.

Torque:

8.4 N*m{86 kgf*cm, 74 in.*lbf}

Connect the 2 ventilation hoses to the cylinder head cover.

Install the 4 ignition coils with the 4 bolts.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Connect the 4 ignition coil connectors.

Install the bracket with the 2 bolts.

Torque:

60 N*m{612 kgf*cm, 44 ft.*lbf}

Install the engine mounting insulator RH with the 4 bolts and 2 nuts.

Torque:

95 N*m{969 kgf*cm, 70 ft.*lbf} for bolt

95 N*m{969 kgf*cm, 70 ft.*lbf} for nut A

52 N*m{530 kgf*cm, 38 ft.*lbf} for nut B

Install the radiator reservoir with the 2 bolts.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Confirm that the wire harness of the crankshaft position sensor is secured to the wire harness clamp bracket through the back of the rib of the timing chain cover.

Install the generator with the 2 bolts.

Torque:

21 N*m{215 kgf*cm, 16 ft.*lbf}for bolt A

52 N*m{530 kgf*cm, 38 ft.*lbf}for bolt B

Install the wire harness clamp.

Install the wire harness clamp bracket with the bolt.

Torque:

8.4 N*m{85 kgf*cm, 74 in.*lbf}

Connect the generator wire with the nut.

Torque:

9.8 N*m{100 kgf*cm, 7 ft.*lbf}

Install the terminal cap.

Connect the generator connector.

Using SST 19 mm socket wrench, loosen the V-ribbed belt tensioner arm clockwise, then install the fan and generator V belt.

SST

09216-42010

NOTICE:

1. Be sure to connect SST and the tools so that they are in line during use.
   
2. When retracting the tensioner, turn it clockwise slowly for 3 seconds or more. Do not apply force rapidly.
   
3. After the tensioner is fully retracted, do not apply force any more than necessary.
   

Install the reinforcement RH with the 4 bolts.

Torque:

96 N*m{989 kgf*cm, 71 ft.*lbf}

Connect the ground cable with the bolt.

Torque:

8.4 N*m{86 kgf*cm, 74 in.*lbf}

Connect the camshaft position sensor connector.

Connect the engine coolant temperature sensor connector.

Connect the engine oil pressure switch connector.

Connect the radio setting condenser connector.

Connect the No. 1 radiator hose.

Apply a light coat of engine oil to the O-ring of the oil control valve.

Install the oil control valve with the bolt.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

NOTICE:

Make sure that the O-ring is not cracked or jammed.

Connect the oil control valve connector.

Install a new gasket onto the cylinder head.

Temporarily tighten the exhaust manifold converter with the 5 nuts.

Tighten the 5 nuts in the sequence shown in the illustration.

Torque:

37 N*m{377 kgf*cm, 27 ft.*lbf}

Install the exhaust manifold heat insulator with the 4 bolts.

Torque:

12 N*m{122 kgf*cm, 9 ft.*lbf}

Connect the air-fuel ratio sensor connector.

Install the stay with the bolt and nut.

Torque:

44 N*m{449 kgf*cm, 32 ft.*lbf}

Install the stay with the bolt and nut.

Torque:

44 N*m{449 kgf*cm, 32 ft.*lbf}

Using a vernier caliper, measure the free length of the compression spring.

Minimum length:

41.5 mm (1.634 in.)

Install a new gasket by hand so that its surface is flush with the exhaust manifold.

NOTICE:

1. Make sure the gasket is facing the correct direction.
   
2. Do not reuse the removed gasket.
   
3. Do not push in the gasket while installing the front exhaust pipe.
   

Install the front exhaust pipe with the 2 compression springs and 2 bolts.

Torque:

43 N*m{438 kgf*cm, 32 ft.*lbf}

Apply a light coat of engine oil to a new O-ring and install it onto the guide.

Install the guide with the bolt.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Install the intake manifold insulator onto the cylinder block.

Install a new gasket into the intake manifold.

Install the intake manifold with the 5 bolts and 2 nuts.

Torque:

30 N*m{305 kgf*cm, 22 ft.*lbf}

Fit the union to check valve hose into the vacuum hose clamp.

Install the wire harness clamp.

Connect the camshaft timing oil control valve connector.

Connect the union to check valve hose to the brake booster.

Install 4 new insulators into the cylinder head.

Install the 2 delivery pipe spacers onto the cylinder head.

Install the fuel delivery pipe together with the 4 fuel injectors, then temporarily tighten the 2 bolts.

NOTICE:

Be careful not to drop the fuel injectors when installing the fuel delivery pipe.

Check that the fuel injector rotates smoothly.
If the fuel injector does not rotate, replace the O-ring.

Tighten the 2 bolts to the specified torque.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Connect the 4 fuel injector connectors.

Install the 2 wire harness clamps.

Connect the fuel main tube.

Push the fuel tube connector until it makes a "click" sound.

Install the fuel pipe clamp.

Install the fuel tube to the fuel hose clamp.

Install a new gasket onto the intake manifold.

Install the throttle body and fuel pipe support with the 4 bolts.

Torque:

30 N*m{306 kgf*cm, 22 ft.*lbf}

Connect the fuel tube into the clamp.

Connect the wire harness clamp.

Connect the throttle position sensor and control motor connector.

for Type A:
Connect the No. 1 throttle body hose to the throttle body.

Connect the No. 2 water by-pass hose to the throttle body.

Connect the water by-pass hose to the throttle body.

Connect the purge line hose to the throttle body.

Install the air cleaner filter element onto the air cleaner case.

Insert the hinge part of the air cleaner cap into the air cleaner case, then hang the 2 hook clamps.

Align the matchmarks of the No. 1 air cleaner hose and throttle body, and then connect the air cleaner hose No. 1 to the throttle body and unfasten the No. 1 air cleaner hose clamp.

NOTICE:

Make sure that the hose clamp is at the correct angle.

Connect the purge line hose to the clamp.

Connect the No. 2 ventilation hose to the air cleaner hose.

Connect the 4 wire harness clamps.

Connect the mass air flow meter connector.

Clean and install the oil drain plug with a new gasket.

Torque:

40 N*m{408 kgf*cm, 30 ft.*lbf}

Add new oil.

Standard capacity:

Item	Specified Condition
Drain and refill with oil filter change	4.2 liters (4.4 US qts, 3.7 Imp. qts)
Drain and refill without oil filter change	4.0 liters (4.2 US qts, 3.5 Imp. qts)
Dry fill	4.9 liters (5.2 US qts, 4.3 Imp. qts)

Install the oil filler cap.

Make sure that there are no fuel leaks after performing maintenance on the fuel system.

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch on (IG), and push the intelligent tester main switch ON.
   

   NOTICE:

   Do not start the engine.

3. Select the Active Test mode on the intelligent tester.
   

   HINT:

   Refer to the intelligent tester operator's manual for further details.

4. Check that there are no leaks from the fuel system.
   

5. Turn the ignition switch off.
   

6. Disconnect the intelligent tester from the DLC3.
   

Tighten the radiator drain cock plug by hand.

Tighten the cylinder block drain cock plug.

Torque:

12.7 N*m{130 kgf*cm, 10 ft.*lbf}

Add TOYOTA Super Long Life Coolant (SLLC) to the radiator reservoir filler opening.

Continue adding TOYOTA SLLC until it is filled to the B line at the base of the reservoir's filler neck.

HINT:

The B line is the lower edge of the inner wall of the filler neck.

Standard capacity:

Item	Specified Condition
A/T	6.4 liters (6.8 US qts, 5.6 Imp. qts)
M/T	6.3 liters (6.7 US qts, 5.5 Imp. qts)

HINT:

1. TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).
   

NOTICE:

Never use water as a substitute for engine coolant.

Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the level of the coolant. If the coolant level drops below the B line, add TOYOTA SLLC to the B line.

Install the radiator reservoir cap.

Start the engine and warm it up until the cooling fan operates. While the cooling fan operates, circulate the coolant for several minutes.

1. Set the air conditioning as follows while warming up the engine.
   

   Item	Specified Condition
   Manual Air Conditioning System	Fan speed: Any setting except OFF
   	Temperature: Toward WARM Air conditioning switch: OFF
   Automatic Air Conditioning System	Temperature: Toward MAX Air conditioning switch: OFF

2. Maintain the engine speed at 2,000 to 2,500 rpm and warm up the engine until the cooling fan operates.
   

   NOTICE:

   1. Make sure that the radiator reservoir still has some coolant in it.
      
   2. Pay attention to the needle of the water temperature meter. Make sure that the needle does not show an abnormally high temperature.
      
   3. If there is not enough coolant, the engine may burn out or overheat.
      
   4. Immediately after starting the engine, if the radiator reservoir does not have any coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the coolant is filled to the B line.
      
   5. Run the engine at 2,000 rpm until the coolant level has stabilized.
      

Press the No. 1 and No. 2 radiator hoses several times by hand to bleed air.

CAUTION:

1. Wear protective gloves.
   
2. Be careful as the radiator hoses are hot.
   
3. Keep your hands away from the radiator fan.
   

Stop the engine and wait until the coolant cools down to ambient temperature.

Check that the coolant level is between the FULL and LOW line.
If the coolant level is below the LOW line, repeat all of the procedures above.
If the coolant level is above the FULL line, drain coolant so that the coolant level is between the FULL and LOW line.

Check for engine coolant leaks (RAV4_ACA30 RM0000017W200QX_01_0001.html).

Start the engine, and check that there are no oil leaks.

Warm up and stop the engine.

When using intelligent tester:

1. Connect the intelligent tester to the DLC3.
   

2. Allow the engine to idle.
   

3. Select the following menu items:
   Powertrain / Engine and ECT / Data List / IGN Advance.
   

4. Read IGN Advance to check the ignition timing.
   

   Standard ignition timing:

   5 to 15° BTDC @ idle
   

5. Check that the ignition timing advances immediately when the engine speed is increased.
   

6. Turn the ignition switch off.
   

7. Disconnect the intelligent tester from the DLC3.
   

When not using intelligent tester:

1. Remove the No. 1 engine cover (RAV4_ACA30 RM000001R3L00BX_01_0005.html).
   





2. Open the ignition cover located to the right of the No. 4 ignition coil.
   

3. Pull out the wire harness from the IG cover.
   

4. Connect a timing light to the wire harness.
   

   NOTICE:

   Use a timing light that detects the first signal.





5. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.
   

   SST

   09843-18040
   

6. Allow the engine to idle and check the ignition timing.
   

   Standard ignition timing:

   8 to 12° BTDC @ idle
   

   HINT:

   Run the engine at 1,000 to 1,300 rpm for 5 seconds, then check that the engine speed returns to the idling speed.

7. Remove SST from the DLC3.
   

8. Allow the engine to idle and check the ignition timing.
   

   Standard ignition timing:

   5 to 15° BTBC
   

9. Check that the ignition timing advances immediately when the engine speed is increased.
   

10. Turn the ignition switch off.
    

11. Remove the timing light.
    

12. Close the IG cover.
    

13. Install the No. 1 engine cover (RAV4_ACA30 RM000001AA900FX_01_0026.html).
    

When using intelligent tester:

1. Turn OFF all the accessories and air conditioning.
   

2. Move the shift lever to P or neutral.
   

3. Connect the intelligent tester to the DLC3.
   

4. Warm up the engine.
   

5. Select the tester menus:
   Powertrain / Engine and ECT / Data List / Engine SPD
   

6. Read Engine SPD to check the idle speed while the radiator-cooling fan is not rotating.
   

   Standard idle speed:

   Item	Specified Condition
   A/T vehicle	610 to 710 rpm
   M/T vehicle	650 to 750 rpm

7. Turn the ignition switch off.
   

8. Disconnect the tester from the DLC3.
   

When not using intelligent tester:

1. Turn OFF all the accessories and air conditioning.
   

2. Move the shift lever to P or neutral.
   

3. Connect SST to 9 (TAC) of the DLC3 terminal, and then connect a tachometer to SST.
   

   SST

   09843-18030
   

4. Warm up the engine.
   

5. Check the idle speed while the radiator-cooling fan is not rotating.
   

   Standard idle speed:

   Item	Specified Condition
   A/T vehicle	610 to 710 rpm
   M/T vehicle	650 to 750 rpm

6. Turn the ignition switch off.
   

7. Remove the tachometer and disconnect SST from the DLC3.
   

Warm up and stop the engine.

Remove the No. 1 engine under cover.

Remove the 4 ignition coils (RAV4_ACA30 RM000001QVM017X_01_0003.html).

Remove the 4 spark plugs.

Disconnect the 4 fuel injector connectors.

Insert a compression gauge into the spark plug hole.

While cranking the engine, measure the compression pressure.

Standard compression pressure:

1,300 kPa (13.3 kgf/cm², 189 psi)

Minimum pressure:

1,000 kPa (10.0 kgf/cm², 145 psi)

Standard difference between each cylinder:

100 kPa (1.0 kgf/cm², 15 psi)

NOTICE:

1. Always use a fully charged battery to obtain an engine speed of 250 rpm or more.
   
2. Check the other cylinders' compression pressures in the same way.
   
3. This measurement must be done as quickly as possible.
   

HINT:

1. If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged.
   
2. If pressure stays low, a valve may be stuck or seated improperly, or there may be leakage in the gasket.
   

Connect the 4 fuel injector connectors.

Install the 4 spark plugs.

Install the 4 ignition coils (RAV4_ACA30 RM000001QVK018X_01_0001.html).

Install the No. 1 engine under cover.

Start and warm up the engine.

Run the engine at 2,500 rpm for approximately 180 seconds.

Insert the CO/HC meter testing probe at least 40 cm (1.3 ft.) into the tailpipe while idling.

Inspect the CO/HC concentration while idling and/or at 2,500 rpm.
If the CO/HC concentration is not as specified, perform troubleshooting.

HINT:

See the table below for possible causes, and then inspect and repair the applicable causes if necessary.

Install the engine cover with the 2 nuts.

Torque:

7.0 N*m{71 kgf*cm, 62 in.*lbf}