Replacing Oil Pan Gasket In 2004 Rav4: Step-By-Step Guide

The oil pan gasket in a 2004 Toyota RAV4 seals the surfaces between the oil pan and the lower part of the engine block. The oil pan is attached to the bottom of the engine and acts as a reservoir for the engine's oil capacity. The oil pan gasket is sandwiched between the bottom of the engine block and the oil pan to keep circulating oil inside the engine. An oil pan gasket replacement for a Toyota RAV4 costs between $382 and $451, with labour costs estimated between $264 and $333, and parts typically priced around $118. However, some gasket products for the Toyota RAV4 can be purchased for as little as $21.49. When changing the oil pan gasket, you will need to jack up the car, drain the oil, and remove the oil pan from the engine.

Jack up the car and let the front end sit on two jack stands

Jack stands are the only safe way to work under a car. Before you begin, make sure you have a friend to help you out. Their automotive knowledge is a bonus but not a necessity. Park your car on level ground and read the manuals for your car and your lifting equipment. Every vehicle has suggested jack points, solid suspension, and frame points.

Now, lift your car with a quality jack. If you're just lifting the front end of your car, you'll need two jack stands. Place the jack under the front subframe and lift. Then, place the two jack stands under the pinch welds in front of the front wheels. Make sure the jack stands are set to equal height and locked in place. Slowly lower the jack until the full weight of the front end rests on the jack stands.

Check that each jack stand is supporting the vehicle – it shouldn’t move if you wiggle it. If there is movement, jack up that corner again and adjust the jack stand. Double-check that all jack stand locks are set properly. Gently shake the vehicle to confirm it is secure. Check that the jack stands are planted flat on the ground and don't move when you shake the car. Once your car passes the shake test, it is safe to work on.

Drain out all the oil

To drain out all the oil from your 2004 Toyota RAV4, you'll need to follow these steps:

Park Your Car

• Find a flat surface to park your car, such as a level spot in your driveway or a garage.
• Make sure you have enough working area around the vehicle.
• Put the car in park, remove the keys, and apply the parking brake.

Warm Up the Engine

• Let the car idle for 5-10 minutes to warm up the engine. This will help the oil flow more freely when you drain it.
• Running the engine for a few minutes will also ensure that the oil is warm when you drain it.

Prepare the Drain Pan

• Place an oil drain pan or container underneath the engine drain plug.
• The engine drain plug is located within 1-2 feet of the front of the vehicle, directly under the engine, at the bottom of the oil pan.
• Use a container that can hold at least twice as much oil as your engine takes to avoid spills.

Remove the Oil Cap

• Open the vehicle's hood and locate the oil cap on top of the engine.
• The cap will be about 2 inches across and should have an oil symbol or the word "oil" on it.
• Unscrew the oil cap counterclockwise and set it aside in a safe place.

Unscrew the Oil Plug

• Use a socket or crescent wrench to unscrew the oil plug counterclockwise.
• Apply inward force as if you're trying to push the plug back into the hole while removing it to avoid spilling oil on your hand.
• Remove the metal washer between the oil pan and the drain plug and set it aside.

Drain the Oil

• Wait for the oil to drain completely. It may take a few minutes as the oil is a thick liquid.
• After the oil has stopped draining, clean the drain plug and the surrounding area with a clean cloth.
• Inspect the washer or gasket for any wear or damage and replace it if necessary.

By following these steps, you will be able to effectively drain all the oil from your 2004 Toyota RAV4. Remember to dispose of the used oil responsibly at designated oil-collection sites or recycling centers.

Remove the oil pan from the engine

To remove the oil pan from a 2004 RAV4, you will need to jack up the car and let the front end sit on two jack stands. This will give you easier access to the oil pan. You will also need to drain out all the oil and do an oil filter change.

The next step is to remove the oil pan bolts. For this, you will need a metric socket wrench, either 10mm or 12mm, with a flexible handle/extension. You will need to work out the bolts.

Once the bolts are removed, you can carefully lift and remove the oil pan from the engine. Be careful not to spill any remaining oil.

It is important to note that Toyota does not use gaskets as part of the factory replacement procedure. Instead, they use FIPG (Form In Place Gasket) or RTV Silicone. This provides a superior bond and seal that lasts much longer than a cork or paper gasket. If you are using RTV Silicone, make sure both gasket surfaces are as clean as possible – no grease, oil, dirt, or debris can remain if you want a good seal.

If you are using a gasket, Felpro and other companies sell gaskets for the oil pan. However, it is recommended to refer to the Factory Service Manual for the correct procedure.

Clean the mating surfaces on the engine block and oil pan

To clean the mating surfaces on the engine block and oil pan of your 2004 Toyota RAV4, you'll need to remove any old gasket material and residue, ensuring the surfaces are smooth and free of debris before installing the new gasket. Here's a step-by-step guide:

• Remove Old Gasket Material: Use a plastic or brass scraper to carefully remove any remaining gasket material from the mating surfaces. Be gentle and use a light touch to avoid gouging the soft aluminum engine block. A plastic scraper or razor blade can help prevent damage to the metal surfaces.
• Clean the Surfaces: Once the majority of the old gasket is removed, apply a degreaser or detergent that breaks down oil. Products like Simple Green, brake cleaner, or acetone can be effective. Use a clean cloth or paper towel to wipe away the degreaser and dissolved oil, turning the black surface into a dirty grey. Then, spray additional degreaser and wipe clean until you have a cleaner grey surface.
• Address Difficult Areas: Some areas, like the fins or recesses, can be challenging to clean. For these areas, spray degreaser between the fins and use a shop rag to push it along, absorbing the dissolved oil. For deep recesses, use a scraper to remove large chunks first, then spray with degreaser and scrub with a cloth.
• Remove Gasket Residue: To remove stubborn gasket residue, you can use a bristle disc attachment on a power drill. Ensure the disc is the appropriate type for aluminum (white or green discs are typically recommended). Work in small sections and be cautious not to apply too much force, as it can create depressions in the aluminum. Use paper towels to catch the dust created by the bristle disc.
• Final Clean: After removing all gasket material and residue, give the surfaces a final clean with degreaser and paper towels or cloths. Ensure that all dust and residue are removed, and the mating surfaces are smooth and ready for the new gasket installation.

Remember to wear appropriate safety gear, including gloves and eye protection, during the cleaning process.

Apply a new gasket or sealant

When applying a new gasket or sealant to your 2004 RAV4, there are a few key steps to follow. Firstly, ensure that the mounting surface is clean and dry. This includes the lower engine block, oil pan, and motor mount. Once these surfaces are prepared, you can apply a thin film of RTV (silicone rubber) to the mounting surface.

Next, position the replacement oil sump gasket against the mounting surface and apply pressure to ensure a good seal. You can then use a few strands of wire, approximately 3-4 inches long, to loosely secure the new gasket in place by twisting them around the gasket. Ensure you remove any insulation from the wire before using it.

At this point, you can install the pan bolt and untwist the wire strands. Refer to the manufacturer's specifications for torque settings as you tighten the oil pan bolt. Some engines require the same torque for the front and rear bolts, while others may specify different torque settings for each.

With the new gasket securely in place, you can proceed to reinstall the oil filter, oil drain plug, and any other necessary components. Refill the crankcase with new motor oil, ensuring you use the correct oil type and level as per the manufacturer's recommendations.

Finally, lower the vehicle and start the engine, allowing it to run for a few minutes. Keep an eye out for any signs of oil leaks. If no leaks are detected, your new gasket has been successfully installed.

Frequently asked questions