OEM 2003 Toyota RAV4 Timing Chain

2003 Toyota RAV4 Parts Questions & Experts Answers

• Q: How to remove the timing chain on 2003 Toyota RAV4?

  A: The process for dismantling the timing chain starts by emptying engine oil before uninstalling components like the RH engine under cover, PS vane pump, ABS actuator, RH engine mounting insulator, drive belt, generator, air cleaner assembly and ignition coils. The procedure begins with PVC hose detachment from the cylinder head cover then continuing with the removal of 8 bolts along with 2 nuts to remove cylinder head cover and its gasket. First, align the Number 1 cylinder at TDC compression position by adjusting the crankshaft pulley position to timing mark 0 while the camshaft and VVT timing sprocket timing marks both align with their bearing caps. Additional crankshaft rotation by 1 revolution will lead to proper alignment. You can remove the crankshaft pulley and bolt by first using SST 09213-54015 and 09330-00021 to loosen the bolt then using SST 09950-50013 if necessary. The service begins with chain tensioner removal through tooling 2 nuts and gasket followed by drive belt tensioner and crankshaft position sensor and oil pan and timing chain cover removal using a torx socket wrench (E10) to separate the stud bolt then continuing with 14 bolts and 2 nuts until the cover can be carefully pried off. The first step involves removing the crank angle sensor plate along with all components of the chain tensioner slipper as well as the chain vibration damper and the timing chain guide. Afterward, extract the timing chain and crankshaft timing sprocket from the engine. Keep the hexagonal wrench section on the camshaft while loosening sprocket bolts to remove exhaust camshaft timing sprocket and VVT timing sprocket as a set. The check should assess both the timing chain elongation and sprocket diameter against the maximum specifications of 122.6 mm (4.827 inch) for the chain length and 1.0 mm (0.039 inch) for the sprocket wear. Monitor the chain tensioner slipper and vibration damper for their tolerance to reach 1.0 mm (0.039 inch) maximum. Test the chain tensioner to check its smooth movement while assessing its locking mechanism and inspect the drive belt tensioner for both oil leakage and sign of cracking. The replacement process for crankshaft front oil seal requires SST 09309-37010 to tap out the old seal and SST 09308-10010, 09950-60010 to install the new one while applying MP grease to the oil seal lip. This procedure must be performed with or without timing chain cover removal. Begin the installation process by first fixing the camshaft timing sprocket and VVT timing sprocket and aligning them properly before torquing the bolts to 54 Nm (550 kgf-cm, 40 ft lbs). Gather the crankshaft timing sprocket and timing chain with their corresponding marked links correctly aligned before installing the two bolts on the chain vibration damper at 9 Nm (90 kgf-cm, 80 inch lbs.). Proceed by connecting the timing chain guide at 9 Nm (90 kgf-cm, 80 inch lbs.) and finally secure the chain tensioner slipper with 19 Nm (195 kgf-cm, 14 ft. lbs.). Fix the crank angle sensor plate with its forward-facing F mark while cleaning old packing before installation with proper application of new packing (Part No. 08826-00080). Tighten all cover bolts and nuts to specified torques before adding the timing chain cover. Place the drive belt tensioner and the crankshaft position sensor in position before mounting the oil pan and the crankshaft pulley which requires alignment of its key while torquing the pulley bolt to 170 Nm (1,735 kgf-cm, 125 ft. lbs.). After setting tension to the chain, install the cylinder head cover with new gasket while applying seal packing then proceed by installing ignition coils, vane pump, generator, RH engine mounting insulator, drive belt, ABS actuator, air cleaner assembly, engine under cover followed by engine oil filling along with starting the engine and leak checking before checking the oil level.