This procedure covers removal and replacement of the intake and exhaust camshafts on the 2019-2024 Toyota RAV4 2.5L I4 engine, including timing chain alignment and valve train components.

Warnings

Tools required

Parts

• Camshaft(s) as needed × 1 — Use OEM specification
• Valve cover gasket × 1 — 11213-0V010
• Timing cover gasket × 1 — 11381-0V020
• Camshaft bearing cap seals × 2 — Use OEM specification
• VVT oil control valve O-rings × 2 — Use OEM specification
• Timing chain tensioner assembly × 1 — 13540-0V010 (recommended replacement)
• Oil drain plug crush washer × 1 — 90430-12031
• Engine oil 0W-20 × 1 — Toyota Genuine 0W-20
• Engine coolant × 1 — Toyota Super Long Life Coolant Pink

Fluids

• Toyota Genuine 0W-20 — 5 qt
• Toyota Super Long Life Coolant (Pink) — 2 qt

Preparation

1. Ensure engine is completely cool and vehicle is on level ground with parking brake applied
2. Disconnect negative battery cable and isolate terminal
3. Remove engine cover and plastic trim pieces from top of engine
4. Drain engine oil completely and install drain plug with new crush washer
5. Drain coolant from radiator and engine block into appropriate container
6. Remove air intake assembly, resonator, and intake tube
7. Label and disconnect all vacuum lines, electrical connectors, and breather hoses from valve cover
8. Support engine weight using engine support bar across fender rails or engine hoist
9. Remove right-side engine mount to allow access to timing cover
10. Take photos of all component positions and timing marks before disassembly

Procedure

1. 1

   Remove valve cover
   Remove ignition coils and spark plugs. Remove PCV valve and hoses. Unbolt valve cover in reverse of tightening sequence (outside to inside). Carefully lift valve cover away, breaking seal if necessary. Clean all gasket surfaces thoroughly with razor blade scraper, ensuring no debris falls into engine.
2. 2

   Remove crankshaft pulley and timing cover
   Remove serpentine belt and tensioner. Use holding tool or impact wrench to remove crankshaft pulley bolt (180 Nm removal torque). Remove harmonic balancer/crankshaft pulley. Remove all timing cover bolts, noting different lengths and locations. Carefully remove timing cover, breaking RTV seal with plastic tool if needed. Clean all gasket surfaces completely.
   ⚠Crankshaft pulley bolt is very tight - ensure proper tool engagement to avoid stripping
   Torque spec

   Crankshaft Pulley Bolt180 Nm (133 lb-ft)

   Harmonic Balancer Bolt180 Nm (133 lb-ft)
3. 3

   Set engine to TDC and verify timing marks
   Rotate crankshaft clockwise using 19mm socket on crankshaft bolt until cylinder #1 is at TDC compression stroke. Verify timing marks: crankshaft keyway should point upward, camshaft timing marks on sprockets should align with cylinder head surface marks, and colored links on timing chain should align with sprocket marks. Take detailed photos of all timing marks.
   ⚠️Only rotate crankshaft clockwise - never counterclockwise during this procedure
4. 4

   Remove timing chain tensioner
   Remove VVT oil control valve solenoids from both intake and exhaust camshafts. Remove timing chain tensioner mounting bolt and carefully extract tensioner assembly. Inspect tensioner for wear - replacement is recommended during camshaft service. If reusing, ensure spring mechanism operates smoothly.
   Torque spec

   VVT Solenoid Bolt10 Nm (7 lb-ft)

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
5. 5

   Secure timing chain and remove cam phasers
   Use wire or specialized tool to secure timing chain to prevent it from falling into engine. Hold each camshaft at hex section with wrench while removing cam phaser bolts (intake and exhaust). Carefully remove cam phasers from camshafts while keeping timing chain supported. Mark intake and exhaust cam phasers clearly.
   ⚠️Do not allow timing chain to drop into timing case - secure it with wire to prevent misalignment
   Torque spec

   Cam Phaser Bolt65 Nm (48 lb-ft)
6. 6

   Remove camshaft bearing caps
   Using a permanent marker, clearly mark each camshaft bearing cap with cylinder number and orientation (intake/exhaust side). Loosen camshaft bearing cap bolts in reverse sequence (outside to inside, multiple passes) to gradually release valve spring pressure. Remove bolts completely and carefully lift off bearing caps, keeping them in exact order. Place caps on clean surface in installation order.
   ⚠Loosen bearing cap bolts gradually in multiple passes to prevent camshaft warping from uneven valve spring pressure
7. 7

   Remove camshafts
   Carefully lift intake and exhaust camshafts straight up out of cylinder head, ensuring not to nick bearing surfaces. Mark each camshaft clearly (intake vs exhaust) if both are being removed. Inspect camshaft lobes for wear, scoring, or discoloration. Measure camshaft journal diameters and lobe heights if wear is suspected. Check camshaft runout if reusing.
8. 8

   Inspect bearing surfaces and journals
   Thoroughly clean all camshaft bearing surfaces in cylinder head using lint-free cloth and appropriate solvent. Inspect bearing journals for scoring, wear, or discoloration. Measure bearing clearances using Plastigage if available (specification typically 0.025-0.076mm). Check camshaft position sensor and inspect reluctor ring condition on camshaft.
   ℹ️Replace camshaft if journal wear exceeds specification or if lobe wear is visible
9. 9

   Install new or serviced camshafts
   Apply clean engine oil liberally to all camshaft journals and lobes. Carefully set camshafts into cylinder head bearing positions, ensuring intake and exhaust are correctly positioned. Verify camshaft timing marks face upward and are approximately aligned. Ensure valve lifters are properly seated before installing camshafts.
10. 10

    Install camshaft bearing caps
    Apply light coat of clean engine oil to bearing cap surfaces. Install bearing caps in exact original positions following your markings - arrows or markings should face forward (timing chain end). Install bearing cap bolts finger-tight initially. Tighten camshaft bearing cap bolts in sequence from center outward in at least 3 passes to 14.0 Nm, ensuring even pressure distribution.
    ⚠Tighten in multiple passes starting from center caps to prevent camshaft binding or bearing damage
    Torque spec

    Camshaft Bearing Cap Bolts14 Nm (10 lb-ft)
11. 11

    Reinstall cam phasers and timing chain
    Verify camshaft and crankshaft are still at TDC position. Install cam phasers onto camshafts with timing marks visible. Engage timing chain with correct colored links aligned to sprocket marks. Hold camshafts steady using wrench on hex section. Apply medium-strength threadlocker to cam phaser bolts and tighten to 65.0 Nm while holding camshaft stationary.
    ⚠️Verify all timing marks are perfectly aligned before tightening cam phaser bolts - incorrect timing causes severe engine damage
    Torque spec

    Cam Phaser Bolt65 Nm (48 lb-ft)
12. 12

    Install timing chain tensioner
    Reset timing chain tensioner by compressing plunger and installing retaining pin or clip. Install tensioner assembly and tighten bolt to 25.0 Nm. Remove retaining pin to allow tensioner to apply pressure to chain. Install VVT oil control valve solenoids with new O-rings and tighten to 10.0 Nm.
    Torque spec

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

    VVT Solenoid Bolt10 Nm (7 lb-ft)
13. 13

    Verify timing and install timing cover
    Manually rotate crankshaft clockwise two complete revolutions and verify all timing marks realign perfectly at TDC. Check for smooth rotation with no binding. Apply continuous bead of RTV sealant to timing cover mating surfaces per Toyota specifications. Install timing cover with new gasket and tighten 10mm bolts to 45.0 Nm and 8mm bolts to 25.0 Nm in proper sequence (refer to service manual for sequence diagram).
    ⚠Allow RTV sealant to cure for minimum 2 hours before adding oil if using FIPG - check specific product requirements
    Torque spec

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

    Install crankshaft pulley and valve cover
    Clean crankshaft pulley mounting surface and install harmonic balancer. Install crankshaft pulley bolt and tighten to 180.0 Nm using appropriate holding tool or impact wrench. Install new valve cover gasket and apply RTV to corners as specified. Install valve cover and tighten bolts in sequence from center outward to 10.0 Nm.
    Torque spec

    Harmonic Balancer Bolt180 Nm (133 lb-ft)

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

    Complete reassembly and fill fluids
    Reinstall right-side engine mount and torque mounting bolts appropriately (27.0 Nm or 47.0 Nm depending on bolt location). Reinstall spark plugs and ignition coils. Reconnect all electrical connectors, vacuum lines, and breather hoses. Install air intake assembly. Fill engine with 5.0 quarts of Toyota Genuine 0W-20 oil. Refill coolant system with Toyota Super Long Life Coolant. Reconnect battery.
    Torque spec

    Mounting Bolts47 Nm (35 lb-ft)

Reassembly

1. Double-check all electrical connectors are properly seated and locked
2. Verify all bolts are torqued to specification and no tools are left in engine bay
3. Ensure serpentine belt is properly routed and tensioned
4. Check that no rags or debris were left inside engine during assembly
5. Verify oil drain plug is tight and oil level is correct on dipstick

Verification

• Start engine and verify no oil leaks from valve cover, timing cover, or cam phaser areas
• Listen for abnormal noises - ticking, rattling, or knocking indicates potential timing or bearing issues
• Verify engine idles smoothly with no misfires or rough running
• Check for proper oil pressure on instrument cluster
• Allow engine to reach operating temperature and recheck for leaks
• Verify VVT system operates correctly by monitoring engine response during acceleration
• Scan for diagnostic trouble codes - P0010, P0011, P0020, P0021 indicate VVT issues
• Road test vehicle to verify normal performance and no check engine light
• Recheck oil level after engine reaches operating temperature and add if necessary
• Inspect timing cover and valve cover for leaks after first 100 miles of operation

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