Lifters/Tappets - All

This procedure covers the removal, inspection, and replacement of all valve lifters (tappets) on the 2012-2017 Toyota Camry 2.5L I4 engine, requiring removal of the camshafts and valve train components.

Warnings

Tools required

Parts

• Valve lifters (bucket-type) × 16 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Valve cover grommets × 5 — Use OEM specification
• Camshaft oil seals × 2 — Use OEM specification
• Timing chain cover gasket × 1 — Use OEM specification
• Intake manifold gasket × 1 — Use OEM specification
• Spark plug tube seals × 4 — Use OEM specification
• Toyota FIPG sealant (Three Bond 1207B or equivalent) × 1 — 08826-00100

Fluids

• Toyota Genuine 0W-20 engine oil — 5 qt

Preparation

1. Verify engine is completely cold before beginning work
2. Disconnect negative battery cable and secure away from terminal
3. Remove engine cover (plastic trim piece on top of engine)
4. Drain engine coolant into suitable container by removing radiator drain plug and lower radiator hose
5. Remove air intake assembly, air filter box, and intake ducting
6. Disconnect and remove ignition coils from all four cylinders
7. Remove spark plugs and store in order
8. Label and disconnect all vacuum lines, PCV hoses, and electrical connectors from valve cover
9. Remove throttle body and intake manifold assembly
10. Install engine support fixture across fender rails or attach engine hoist with load leveler
11. Remove right-side engine mount and bracket to access timing chain area
12. Set up organized workspace with labeled magnetic trays for lifters (numbered 1-16)
13. Have clean, lint-free shop towels ready to cover open cylinder head ports

Procedure

1. 1

   Remove valve cover and gasket
   Remove valve cover bolts in reverse of tightening sequence (start from outer bolts working inward). Carefully lift valve cover straight up to avoid damaging gasket mating surfaces. Remove and discard old gasket and grommets. Clean all gasket surfaces thoroughly with plastic scraper and brake cleaner. Inspect cylinder head surface for warping or damage.
   Torque spec

   Cover Bolts16 Nm (12 lb-ft)
2. 2

   Rotate engine to TDC compression stroke cylinder 1
   Rotate crankshaft clockwise (using 19mm socket on crankshaft pulley bolt) until timing marks on camshaft sprockets align with their respective marks on the bearing caps. Verify timing marks on crankshaft pulley align with 0-degree mark on timing cover. This is TDC for cylinder 1. Take photos of all timing marks for reference. DO NOT rotate engine again until reassembly is complete.
   ⚠️Confirm TDC position by checking that both intake and exhaust cam lobes for cylinder 1 point upward away from valves. Incorrect positioning will cause timing errors.
3. 3

   Remove timing chain cover and secure timing chain
   Remove bolts securing upper timing chain cover. Carefully remove cover, noting locations of different bolt lengths. Visually inspect timing chain tension and guide condition. Use wire or zip ties to secure timing chain to camshaft sprockets in multiple locations to prevent chain from falling or losing position. Mark chain-to-sprocket relationship with paint pen on at least two teeth per sprocket.
   ⚠If timing chain falls into lower timing case during this procedure, complete engine front cover removal will be required. Secure chain thoroughly.
   Torque spec

   Cover Bolts16 Nm (12 lb-ft)
4. 4

   Remove camshaft timing sprockets
   Hold each camshaft steady using wrench on hex portion of camshaft (between journal 2 and 3). Remove camshaft sprocket bolts. Carefully slide sprockets forward off camshafts while keeping timing chain secured to sprockets with wire. Support sprockets with wire or cord suspended from hood or support fixture to prevent chain tension loss. Do not allow chain to drop or become slack.
   ⚠️Maintain tension on timing chain throughout this step. Chain must remain engaged with crankshaft sprocket below.
5. 5

   Mark and remove camshaft bearing caps
   Using paint pen or punch, mark each camshaft bearing cap with its position number and orientation arrow pointing toward front of engine. Caps are numbered 1-5 on intake and 1-5 on exhaust, front to back. Loosen bearing cap bolts in reverse sequence: start from outer caps (1 and 5) and work toward center cap, loosening each bolt gradually in multiple passes (1/4 turn each). Remove bolts and caps, keeping them in exact order.
   ⚠️Bearing caps MUST return to exact original positions. They are not interchangeable. Incorrect installation will cause immediate camshaft seizure and destruction.
   ⚠Loosen bearing cap bolts gradually and evenly. Uneven loosening can warp camshaft or crack bearing caps.
   Torque spec

   Camshaft Bearing Cap Bolts14 Nm (10 lb-ft)
6. 6

   Remove camshafts
   Carefully lift intake camshaft straight up out of cylinder head, keeping it level to avoid binding. Remove exhaust camshaft in same manner. Place camshafts on clean padded surface. Inspect camshaft lobes, journals, and bearing surfaces for scoring, wear, or damage. Measure journal diameters if any wear is suspected. Remove and discard camshaft oil seals from front of head.
   ℹ️Cover open cylinder head with clean shop towels to prevent foreign material entry.
7. 7

   Remove and document all valve lifters
   Using magnet or lifter removal tool, carefully extract each lifter (bucket) from its bore. Place immediately in corresponding numbered position in magnetic tray (intake 1-8, exhaust 1-8). Remove valve shim from top of each valve stem and place with corresponding lifter. Record shim thickness markings (stamped on shim) for each position in notebook or photo documentation. Inspect each lifter bottom surface for scoring, pitting, or uneven wear patterns.
   ⚠Lifter-to-bore clearance is precise. If lifters are mixed up, valve adjustment will be incorrect and potential lifter binding can occur.
   ℹ️Shim thickness is critical for valve clearance. Losing track of shim positions will require complete valve clearance measurement and shim selection procedure.
8. 8

   Inspect lifter bores and valve stems
   Clean each lifter bore in cylinder head with clean lint-free cloth. Inspect bores for scoring or debris. Wipe each valve stem clean and inspect for wear or damage. Check valve spring retainers and keepers for security. If replacing lifters due to noise, inspect camshaft lobes corresponding to noisy lifter positions for wear or damage. Measure lifter outside diameter and bore inside diameter if wear is suspected (specification: lifter OD 31.980-31.995mm, bore ID 32.000-32.025mm, clearance 0.005-0.045mm).
9. 9

   Install new or cleaned lifters with correct shims
   If reusing lifters, clean each thoroughly with brake cleaner and dry completely. Lubricate each lifter with clean engine oil on sides and base. Install each lifter into its exact original bore position. Place corresponding shim on top of valve stem, then seat lifter over shim. If installing new lifters, valve clearance MUST be measured and correct shims selected (beyond scope of this procedure—consult service manual). Verify all 16 lifters are installed in correct positions.
   ⚠New lifters require valve clearance adjustment procedure to select correct shim thicknesses. Incorrect clearance will cause valve train damage.
10. 10

    Prepare and install camshafts
    Thoroughly clean camshaft journals and cylinder head bearing surfaces with clean solvent. Lubricate all camshaft journals and lobes liberally with clean engine oil or assembly lube. Install new camshaft oil seals in front of cylinder head using seal driver (drive until flush). Carefully lower exhaust camshaft into place, then intake camshaft. Verify camshaft timing gear mounting flanges are positioned for correct timing (intake cam knock pin at 12 o'clock, exhaust cam knock pin at 9 o'clock when at TDC cylinder 1).
    ⚠Ensure no lifters are positioned under camshaft base circle during installation. Rotate lifters slightly if needed before lowering camshaft.
11. 11

    Install camshaft bearing caps in sequence
    Apply light coat of clean engine oil to bearing cap surfaces. Install each bearing cap in its exact original position with orientation marks pointing toward front of engine. Install all cap bolts finger-tight first. Tighten bearing cap bolts in three passes using proper sequence: start with center cap (3), then caps 2 and 4, finally caps 1 and 5. First pass: 5 Nm, second pass: 10 Nm, final pass: 14 Nm. Tighten in small increments working from center outward. After final torque, verify camshafts rotate smoothly by hand.
    ⚠️Incorrect bearing cap position or torque sequence will cause immediate catastrophic camshaft failure. Triple-check cap positions before tightening.
    ⚠If camshaft does not rotate smoothly after torquing, DO NOT force it. Remove caps and verify lifter positions and bearing cleanliness.
    Torque spec

    Camshaft Bearing Cap Bolts14 Nm (10 lb-ft)
12. 12

    Reinstall camshaft timing sprockets
    Verify timing chain is still properly secured and positioned. Align camshaft knock pins with sprocket slots. Slide sprockets onto camshafts while carefully removing wire securing chain to sprockets. Verify timing marks on chain align with sprocket marks. Verify painted timing reference marks match original positions. Install sprocket bolts and tighten while holding camshaft hex steady. Verify crankshaft is still at TDC. Recheck all timing marks before proceeding.
    ⚠️This is final timing verification point. If timing marks do not align perfectly, disassemble and correct before proceeding. Starting engine with incorrect timing will destroy engine.
13. 13

    Reinstall timing chain cover
    Clean timing chain cover and cylinder head mating surfaces thoroughly. Apply continuous 2-3mm bead of Toyota FIPG sealant to cover mating surface. Install cover within 3 minutes of sealant application. Install cover bolts in correct positions (note different lengths) and tighten in sequence from center outward. Allow sealant to cure for 30 minutes minimum before adding oil.
    ⚠Too much sealant can break off and clog oil passages. Too little will cause oil leaks. Apply consistent 2-3mm bead.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)
14. 14

    Install valve cover with new gasket
    Install new valve cover gasket into groove in valve cover. Install new rubber grommets in all bolt locations. Apply small dab of sealant at front corners where timing chain cover meets cylinder head. Place valve cover onto cylinder head, ensuring gasket seats properly. Install all valve cover bolts finger-tight, then torque in sequence from center outward in two passes: first pass 5 Nm, final pass 10 Nm.
    ⚠Over-torquing valve cover bolts will distort cover and cause oil leaks. Use torque wrench for final tightening.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)
15. 15

    Reinstall remaining components and fill fluids
    Reinstall right-side engine mount and bracket, tightening mounting bolts to specification. Reinstall intake manifold with new gasket, tightening bolts to specification. Reinstall throttle body. Reconnect all vacuum lines, PCV hoses, and electrical connectors. Install spark plugs (do not over-torque). Reinstall ignition coils. Reinstall air intake system. Fill cooling system with Toyota Super Long Life Coolant. Fill engine with 5 quarts Toyota Genuine 0W-20 oil. Reconnect battery.
    Torque spec

    Intake Manifold Bolts25 Nm (18 lb-ft)

Reassembly

1. Double-check all electrical connectors are fully seated and locked
2. Verify all vacuum lines are connected to correct ports
3. Confirm no tools or rags remain in engine bay
4. Verify oil drain plug is tight and oil filter is properly installed
5. Check coolant level in reservoir and radiator

Verification

• With ignition off, manually rotate crankshaft two complete revolutions and verify timing marks return to TDC alignment exactly
• Check for any binding or unusual resistance when rotating engine by hand
• Perform initial start with scan tool connected to monitor for timing-related fault codes
• Start engine and listen carefully for abnormal valve train noise (ticking, knocking, or rattling)
• Allow engine to reach operating temperature and verify no oil leaks from valve cover or timing cover
• Check oil pressure gauge or warning light for proper oil pressure
• Verify smooth idle and no misfires using scan tool
• Road test vehicle and verify normal acceleration and no Check Engine Light
• After 100 miles, re-check valve cover bolts for proper torque and inspect for any oil seepage
• If any valve train noise is present after lifter replacement, valve clearance adjustment may be required

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