This procedure covers removal and replacement of all rocker arms on the 2AR-FE 2.5L I4 engine, including camshaft removal, inspection, and proper reassembly with timing verification.

Warnings

Tools required

Parts

• Valve cover gasket × 1 — 11213-36011
• Valve cover grommets/seals × 1 — Use OEM specification
• Rocker arm assembly (if damaged) × 16 — Use OEM specification
• Camshaft oil seals × 2 — 90311-38017
• Engine oil × 1 — Toyota Genuine 0W-20

Fluids

• Toyota Genuine 0W-20 — 5 qt

Preparation

1. Ensure engine is completely cold to the touch
2. Disconnect negative battery cable and wait 90 seconds for airbag system to discharge
3. Remove engine cover by pulling upward on front and rear clips
4. Drain engine oil completely and install drain plug with new washer
5. Support engine from above using engine hoist or support fixture attached to lifting eyes
6. Remove right-side engine mount to allow engine to be lowered slightly for clearance
7. Label and disconnect all vacuum hoses, electrical connectors, and PCV hoses from valve cover
8. Remove ignition coils (4x 10mm bolts) and spark plugs to allow free engine rotation
9. Rotate engine to TDM on cylinder #1 (both camshaft timing marks aligned at 12 o'clock position)
10. Mark timing chain-to-camshaft sprocket relationship with paint pen on three points per sprocket

Procedure

1. 1

   Remove valve cover
   Remove valve cover bolts in reverse of tightening sequence (outside to inside pattern). Gently tap cover with rubber mallet if stuck. Lift cover straight up to avoid damaging gasket surface on cylinder head.
   Torque spec

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

   Remove camshaft position sensors
   Remove both intake and exhaust camshaft position sensors located at the front of cylinder head. Disconnect electrical connectors and remove single bolt from each sensor. Store sensors in clean area to prevent contamination.
   Torque spec

   Sensor Bolts11 Nm (8 lb-ft)
3. 3

   Remove timing chain cover (upper)
   Remove the upper timing chain cover bolts that are accessible from valve cover area. This provides access to camshaft sprocket bolts. Keep track of different bolt lengths and locations.
   Torque spec

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

   Secure timing chain and remove camshaft sprockets
   Use wire or zip ties to secure timing chain to prevent it from falling into lower timing cover. Hold each camshaft with holding tool and remove camshaft sprocket bolts (12mm). Carefully remove sprockets while maintaining timing chain position. Do not allow chain to drop or rotate.
   ⚠If timing chain drops into lower cover, oil pan removal may be required for retrieval. Keep chain secured at all times.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
5. 5

   Remove camshaft bearing caps
   Loosen camshaft bearing cap bolts in multiple passes working from outside toward center, 1/4 turn at a time to gradually release valve spring pressure. Note that bearing caps are numbered and directional - mark positions if numbers are unclear. Remove all bearing cap bolts and caps, keeping them in exact order.
   ⚠Loosening bearing caps unevenly or too quickly can warp camshafts or crack bearing caps. Use gradual, sequential loosening pattern.
   Torque spec

   Rocker Arm Shaft Bolts25 Nm (18 lb-ft)
6. 6

   Remove camshafts
   Carefully lift both intake and exhaust camshafts straight up from cylinder head. Mark each camshaft for intake/exhaust identification. Place camshafts on clean padded surface with lobes facing up to prevent damage.
7. 7

   Remove rocker arms and hydraulic lash adjusters
   Remove all 16 rocker arms from cylinder head, keeping each with its corresponding hydraulic lash adjuster. Place rocker arms in numbered tray in exact cylinder order (1-4, intake/exhaust). Remove hydraulic lash adjusters and store upright in oil to prevent air from entering. Note any rocker arms showing wear, scoring, or pitting for replacement.
   ℹ️Hydraulic lash adjusters must be stored upright in clean engine oil. If air enters adjusters, engine may have excessive valve noise until adjusters re-prime (up to 30 minutes of running).
8. 8

   Inspect components
   Inspect all rocker arm contact surfaces for scoring, pitting, or uneven wear. Check camshaft lobes for wear patterns - lobes should have smooth, uniform surface. Measure camshaft bearing journals with micrometer if wear is suspected. Inspect cylinder head cam bearing surfaces for scoring. Replace any damaged components.
9. 9

   Clean all surfaces
   Thoroughly clean cylinder head deck surface, camshaft bearing surfaces, and valve cover mating surface. Remove all old gasket material using plastic scraper. Clean oil passages with brake cleaner and compressed air. Ensure no debris enters oil return passages.
10. 10

    Install rocker arms and lash adjusters
    Coat hydraulic lash adjusters with clean engine oil and install into original bores. Install rocker arms in original positions with roller contacting valve stem tip. Apply engine assembly lube to all rocker arm contact points and camshaft lobes.
11. 11

    Install camshafts
    Apply clean engine oil to all camshaft journals and lobes. Install intake camshaft (marked IN or with VVT-i actuator) and exhaust camshaft (marked EX) into correct positions. Ensure camshaft timing marks are positioned at 12 o'clock and aligned with cylinder head timing marks. Verify timing pin holes in camshafts are properly positioned.
    ⚠Installing camshafts reversed (intake/exhaust swapped) will cause immediate engine damage. Verify markings before installation.
12. 12

    Install bearing caps and torque
    Install camshaft bearing caps in numbered order with arrows pointing toward timing chain end. Apply light coat of engine oil to bolt threads. Tighten bearing cap bolts evenly in multiple passes from center outward, gradually compressing valve springs. Final torque in sequence from center to ends.
    ℹ️Tighten bearing caps evenly and gradually. Uneven tightening can bind camshafts or crack bearing caps.
    Torque spec

    Rocker Arm Shaft Bolts25 Nm (18 lb-ft)
13. 13

    Install camshaft sprockets
    Verify timing chain is properly positioned on crankshaft sprocket. Align timing marks on chain with marks made during disassembly. Install camshaft sprockets ensuring timing marks align perfectly. Install and hand-tighten sprocket bolts. Hold camshafts with holding tool and torque sprocket bolts to specification.
    ⚠Verify timing marks alignment three times before proceeding. Incorrect timing will cause valve-to-piston contact and catastrophic engine damage.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
14. 14

    Install timing chain cover and sensors
    Clean timing chain cover mating surfaces and install upper timing chain cover with new gasket or sealant per Toyota specifications. Torque cover bolts to specification. Install camshaft position sensors with new O-rings coated in engine oil.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)

    Sensor Bolts11 Nm (8 lb-ft)
15. 15

    Install valve cover
    Install new valve cover gasket and grommets into valve cover grooves. Apply small bead of Toyota sealant to corners where gasket meets timing chain cover. Position valve cover carefully onto cylinder head. Install bolts and tighten in sequence from center outward in two steps: first to 5 Nm, then to final specification.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)

Reassembly

1. Reinstall right-side engine mount and torque to specification
2. Remove engine support fixture
3. Install spark plugs with anti-seize and torque to 18 Nm
4. Install ignition coils and torque bolts to 10 Nm
5. Reconnect all vacuum hoses, PCV hoses, and electrical connectors per labels
6. Install engine cover by pressing down until clips engage
7. Reconnect negative battery cable

Verification

• Fill engine with correct amount of fresh 0W-20 engine oil (5.0 quarts)
• Manually rotate engine two complete revolutions by hand using 19mm socket on crankshaft bolt - verify smooth rotation with no binding
• Verify camshaft timing marks realign perfectly after two crankshaft rotations
• Start engine and verify no unusual valve train noise - some ticking for first 30 seconds is normal while lash adjusters prime
• Check for oil leaks around valve cover gasket and camshaft seals
• Allow engine to reach operating temperature and verify smooth idle
• Scan for diagnostic trouble codes - no camshaft timing codes should be present
• Road test vehicle and verify normal engine performance under load

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