This procedure replaces a single hydraulic valve lifter on the 2019-2024 Toyota RAV4 2.5L I4 engine, requiring removal of the valve cover, camshafts, and rocker arms to access the lifter.

Warnings

Tools required

Parts

• Hydraulic valve lifter × 1 — Use OEM specification
• Valve cover gasket kit × 1 — Use OEM specification
• Camshaft bearing cap seal (if damaged) × 1 — Use OEM specification
• Engine oil × 1 — Toyota Genuine 0W-20
• Silicone sealant (Toyota Genuine Seal Packing Black 08826-00080) × 1 — 08826-00080

Fluids

• Toyota Genuine 0W-20 — 5 qt

Preparation

1. Ensure engine is completely cold to the touch (minimum 2 hours after last operation)
2. Disconnect negative battery cable and wait 90 seconds for airbag system discharge
3. Remove engine cover by pulling upward on front clips
4. Drain engine oil completely and note oil condition (metal particles indicate additional damage)
5. Position vehicle on level surface and engage parking brake
6. Identify which lifter needs replacement by cylinder number and intake/exhaust position
7. Take multiple reference photos of engine bay, timing marks, and component positions before starting
8. Label or photograph all electrical connectors before disconnection

Procedure

1. 1

   Remove intake air system and ignition coils
   Disconnect the air intake tube from throttle body. Remove ignition coils from all four cylinders by unplugging electrical connectors and removing the 10mm mounting bolts. Label each coil with cylinder number for correct reinstallation. Set aside in clean area.
2. 2

   Remove valve cover assembly
   Disconnect PCV hoses and any vacuum lines attached to valve cover. Remove the valve cover bolts in reverse sequence (outside to inside pattern). Carefully lift valve cover straight up to avoid damaging gasket surfaces. If stuck, gently tap with plastic mallet - do not pry. Inspect valve cover gasket condition.
   Torque spec

   Cover Bolts16 Nm (12 lb-ft)
3. 3

   Rotate engine to TDC and mark timing positions
   Rotate crankshaft clockwise using 22mm socket on crankshaft pulley bolt until cylinder #1 is at Top Dead Center (TDC) on compression stroke. Verify timing marks on both camshaft gears align with marks on timing chain cover. Use paint pen to mark exact relationship between camshaft gears and timing chain links. Mark chain-to-gear position on both intake and exhaust gears. Take clear photos of all timing marks.
   ⚠️Incorrect timing marks will result in valve-to-piston contact and complete engine failure. Verify TDC position three times before proceeding.
4. 4

   Remove camshaft timing gear assemblies
   Using Toyota SST 09960-10010 or equivalent camshaft holding tool, secure the intake camshaft gear. Remove the intake camshaft gear bolt (reverse threaded - turn clockwise to loosen). Carefully remove gear while keeping timing chain supported - do not let chain fall into timing cover. Wire or tie chain in position. Repeat process for exhaust camshaft gear. Keep gears in order and protected from contamination.
   ⚠️Do not allow timing chain to fall into timing cover. Secure chain with wire or zip ties to prevent misalignment.
5. 5

   Mark and remove camshaft bearing caps
   Before removal, verify all camshaft bearing caps are marked with position indicators (typically numbered 1-5 from timing chain end, with arrow showing front). If marks are unclear, create detailed marking system with paint pen. Loosen bearing cap bolts in multiple passes working from outside bolts toward center, loosening each bolt 1/4 turn at a time to prevent camshaft distortion. Remove bolts completely and carefully lift bearing caps straight up. Keep caps in exact order on clean surface.
   ⚠️Bearing caps are machined as matched sets. Swapping positions will cause immediate bearing failure and camshaft destruction.
6. 6

   Remove camshafts and rocker arms
   Carefully lift both intake and exhaust camshafts straight up from cylinder head. Inspect cam lobes for wear or scoring. Remove rocker arms corresponding to the cylinder with failed lifter (identify by counting from front of engine). Place rocker arms on clean surface in order. Note orientation of each rocker arm.
7. 7

   Remove and inspect failed lifter
   Using magnetic pickup tool, extract the failed hydraulic lifter from its bore. Inspect lifter for scoring, wear, or collapse. Inspect lifter bore in cylinder head for scoring or debris. Clean bore thoroughly with lint-free cloth. Measure bore diameter if dial bore gauge available - excessive wear indicates cylinder head damage. Check adjacent lifters for similar condition.
   ⚠If multiple lifters show wear or if metal particles were found in oil, complete lifter replacement and oil system flush is recommended.
8. 8

   Prepare and install new lifter
   Remove new lifter from packaging. Submerge new lifter in clean engine oil for 5 minutes to prime internal check valve. Do not press plunger fully - leave partial charge in lifter. Apply clean engine oil to exterior of lifter body. Insert lifter into bore with gentle twisting motion, ensuring it seats fully in bore. Lifter should drop into place with light finger pressure only.
   ⚠Never install a dry lifter. Improper priming causes noisy operation and premature failure.
9. 9

   Reinstall rocker arms
   Coat rocker arm contact surfaces with clean engine oil. Reinstall rocker arms in exact original positions over valve stems and lifters. Verify each rocker arm seats properly on both valve stem and lifter, and moves freely without binding.
10. 10

    Reinstall camshafts and bearing caps
    Apply light coat of clean engine oil to all camshaft journals and lobes. Position both camshafts in cylinder head with cam lobes for cylinder #1 pointing upward (engine at TDC position). Install bearing caps in exact original positions following marked numbers and directional arrows. Install all bearing cap bolts finger-tight first. Tighten bolts in multiple passes from center outward, following manufacturer sequence, making several passes with progressive tightening. Final torque according to specification, ensuring camshafts rotate freely.
    ⚠️Bearing caps installed in wrong positions or backwards will seize camshafts immediately on startup.
11. 11

    Reinstall timing gears and verify timing
    Apply light threadlocker to camshaft gear bolts. Position timing chain on intake camshaft gear aligning paint marks made during disassembly. Install intake gear onto camshaft while holding chain in position. Hand-tighten bolt. Repeat for exhaust gear, ensuring all timing marks align perfectly with original positions. Use holding tool to secure each gear and torque bolts to specification (reverse threaded). Rotate crankshaft two complete revolutions and recheck timing mark alignment.
    ⚠️Verify timing marks three times after torquing. One link off will cause valve damage.
12. 12

    Clean and prepare valve cover mating surfaces
    Thoroughly clean valve cover gasket surface and cylinder head mating surface with plastic scraper. Remove all old gasket material and oil residue using lint-free cloths and brake cleaner. Inspect surfaces for damage or warping. Install new valve cover gasket into valve cover groove, ensuring proper seating. Apply thin bead of Toyota Genuine Seal Packing Black to two front corners where timing chain cover meets cylinder head.
13. 13

    Reinstall valve cover
    Position valve cover carefully over cylinder head, aligning all bolt holes and ensuring PCV passages align. Install all valve cover bolts finger-tight. Following proper tightening sequence (inside to outside pattern), torque all bolts in three progressive passes to specification. Do not overtighten as this will damage gasket and cause oil leaks.
    Torque spec

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

    Reinstall ignition coils and intake system
    Reinstall ignition coils to correct cylinders using labeled positions. Torque coil mounting bolts to specification if provided, or 8-10 Nm. Reconnect all electrical connectors. Reinstall air intake system and any removed vacuum hoses or sensors. Reconnect PCV hoses to valve cover.
15. 15

    Refill engine oil and prime system
    Install new oil filter if not already changed. Refill engine with 5.0 quarts of Toyota Genuine 0W-20 engine oil. With spark plugs or ignition coils disabled (to prevent starting), crank engine for 5 seconds to build oil pressure. Wait 30 seconds and repeat two more times. Reinstall any disabled components. Start engine and verify oil pressure light extinguishes immediately. Listen for any abnormal valve train noise.
    ⚠If check engine light illuminates or unusual noises occur, shut down immediately and recheck valve timing and bearing cap positions.

Reassembly

1. Verify all electrical connectors are fully seated and locked
2. Double-check that all timing marks remain aligned after installation
3. Ensure no tools or parts were left in engine bay
4. Reinstall engine cover
5. Reconnect negative battery cable

Verification

• Start engine and verify oil pressure warning light extinguishes within 2 seconds
• Listen for valve train noise - new lifter may produce slight noise for first 30 seconds as it fully primes
• Let engine idle for 5 minutes and verify smooth operation with no ticking or tapping
• Check for oil leaks around valve cover gasket, paying attention to front corners
• Rev engine gently to 2500 RPM several times and verify smooth operation
• Check engine oil level after engine reaches operating temperature and shut down for 5 minutes
• Scan for diagnostic trouble codes - timing-related codes indicate misalignment
• Road test vehicle under light load and verify no unusual noises or performance issues
• Re-check valve cover for leaks after first 50 miles of operation

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