Complete replacement of all valve lifters/tappets on the 2019-2024 Toyota RAV4 2.5L I4 engine, requiring removal of camshafts and timing components.

Warnings

Tools required

Parts

• Valve lifters/tappets (16 pieces) × 16 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Camshaft oil seal (intake) × 1 — Use OEM specification
• Camshaft oil seal (exhaust) × 1 — Use OEM specification
• Timing chain cover gasket × 1 — Use OEM specification
• VVT-i oil control valve O-rings × 2 — Use OEM specification
• Valve adjustment shims (assorted sizes) × 1 — Use OEM specification
• Engine oil × 5 — Toyota Genuine 0W-20

Fluids

• Toyota Genuine 0W-20 — 5 qt

Preparation

1. Ensure engine is completely cold. Allow at least 3 hours cooling time if recently operated.
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 into appropriate container.
5. Remove air intake assembly and air filter housing.
6. Label and disconnect all electrical connectors, vacuum hoses, and breather hoses from valve cover.
7. Remove ignition coils (four 10mm bolts) and spark plugs. Store in order.
8. Support engine from below using appropriate jack with block of wood on oil pan.
9. Remove right-side engine mount to provide access to timing cover.
10. Prepare clean work surface with labeled containers for parts organization.
11. Have smartphone or camera ready to photograph timing marks and component positions.

Procedure

1. 1

   Remove valve cover
   Remove valve cover bolts in reverse of tightening sequence (outside to inside pattern). Carefully lift valve cover off. If stuck, gently tap with rubber mallet - do not pry between sealing surfaces. Remove and discard old gasket material.
   Torque spec

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

   Rotate engine to TDC cylinder #1
   Using 19mm socket on crankshaft pulley bolt, rotate engine clockwise until timing marks on camshaft sprockets align with marks on timing chain cover. Verify cylinder #1 is on compression stroke by checking that both intake and exhaust cam lobes point away from cylinder #1. Mark all timing positions with paint pen including chain-to-sprocket relationship.
   ⚠️This is the critical timing reference point. Triple-check alignment before proceeding. Take multiple photos from different angles.
3. 3

   Remove timing chain cover upper section
   Remove bolts securing upper timing chain cover (mixture of 10mm bolts and clips). Note bolt lengths and positions as they vary. Carefully separate cover from cylinder head. Do not disturb lower timing cover or crankshaft seal area.
   Torque spec

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

   Lock timing chain to sprockets
   Before removing any camshaft components, use zip ties or wire to secure timing chain to both camshaft sprockets at multiple points. This prevents chain from slipping on sprockets or falling into engine. Verify engine is still at TDC and marks are aligned.
   ⚠️Chain must remain positively locked to sprockets throughout camshaft removal. If chain jumps timing, complete disassembly and reset will be required.
5. 5

   Remove camshaft sprocket bolts
   Hold each camshaft with appropriate holding tool or adjustable wrench on hex section. Remove camshaft sprocket bolts (one per camshaft). Do NOT remove sprockets from chain - leave them hanging on chain with zip ties securing position. Mark intake vs exhaust sprocket clearly.
   ⚠Camshaft will try to rotate due to valve spring pressure. Ensure holding tool is secure before loosening bolts.
6. 6

   Mark and remove camshaft bearing caps
   Camshaft bearing caps are numbered and must return to exact original positions. Verify factory markings are visible or create your own marks indicating position and orientation (intake vs exhaust, cylinder number, front/rear orientation). Loosen bearing cap bolts in multiple passes working from outer caps toward center, 1/4 turn at a time to gradually release valve spring tension. Remove bolts and caps, keeping them organized in order.
   ⚠️Bearing caps are NOT interchangeable. Installing in wrong position will cause immediate bearing failure and engine destruction.
   ⚠Loosen gradually and evenly. Uneven loosening can bend camshaft or damage bearing caps due to valve spring pressure.
   Torque spec

   Camshaft Bearing Cap Bolts14 Nm (10 lb-ft)
7. 7

   Remove camshafts
   Carefully lift out both intake and exhaust camshafts. Keep them separate and labeled. Support camshaft sprockets with wire to prevent them from falling. Inspect camshaft lobes and journals for wear, scoring, or damage. Measure journal diameters if any wear is suspected.
   ℹ️Do not allow camshaft sprockets to rotate or drop into timing cover area. Keep them supported and wired in position.
8. 8

   Remove and inspect lifters
   Remove all 16 valve lifters (tappets) from their bores in cylinder head. Keep lifters organized by cylinder and valve position if reusing for measurement reference. Use magnetic pickup tool if needed. Inspect lifter bores in cylinder head for scoring or damage. Clean bores thoroughly with lint-free cloth and inspect with flashlight. Measure lifter bore diameter if wear is suspected.
   ⚠Lifter bores must be pristine. Any scoring or out-of-round condition requires cylinder head replacement or professional machining.
9. 9

   Clean and prepare cylinder head surface
   With all lifters removed, thoroughly clean cylinder head surface, lifter bores, and camshaft journals. Remove any sludge, carbon, or debris. Use compressed air to blow out oil passages. Wipe all surfaces with clean lint-free rags. Inspect camshaft bearing surfaces in cylinder head for any scoring or damage. Cover cylinder head openings with clean shop towels to prevent debris entry.
   ℹ️Absolute cleanliness is critical. Any debris will be circulated through engine causing rapid wear or failure.
10. 10

    Install new lifters
    Coat each new lifter with clean engine oil before installation. Install all 16 new lifters into their bores, ensuring they slide freely without binding. Each lifter should drop into place with only gentle finger pressure. Verify lifters rotate freely in their bores. Apply additional engine oil to top of each lifter.
    ⚠Lifters must slide freely in bores. Any binding indicates bore damage or incorrect lifter specification.
11. 11

    Install camshafts
    Generously lubricate all camshaft journals and lobes with clean engine oil. Verify timing chain sprockets are still properly positioned and secured. Carefully install intake and exhaust camshafts into their correct positions with sprockets aligned to timing marks. Ensure camshaft sprocket pins engage sprocket holes correctly. Rotate camshafts slightly if needed to ensure lobes are not putting excessive pressure on any valves.
    ⚠️Verify correct camshaft orientation. Intake and exhaust camshafts are different and not interchangeable.
12. 12

    Install camshaft bearing caps and torque
    Install camshaft bearing caps in their exact original positions and orientations. Hand-tighten all bolts first. Torque bearing cap bolts in 3 progressive passes: first pass 5 Nm, second pass 10 Nm, final pass 14 Nm (10 lb-ft). Follow sequence from center caps outward, alternating intake and exhaust sides. Verify camshafts rotate smoothly by hand after torquing.
    ⚠️Tightening sequence and multiple passes are critical. Single-pass or incorrect sequence will damage bearings or bend camshaft.
    Torque spec

    Camshaft Bearing Cap Bolts14 Nm (10 lb-ft)
13. 13

    Install camshaft sprocket bolts
    Remove temporary zip ties from timing chain. Verify timing marks are still perfectly aligned. Hold each camshaft with holding tool and install sprocket bolts. Torque camshaft sprocket bolts per manufacturer specification (typically 50-65 Nm, but verify with service manual as this torque is not in provided list). Triple-check all timing marks alignment.
    ⚠️Final verification of timing alignment. Any misalignment will cause engine damage on startup.
14. 14

    Verify valve clearances
    With new lifters installed, valve clearances must be checked and adjusted. Rotate engine two full revolutions clockwise to settle components. Check valve clearance on all 16 valves using feeler gauges with cam lobes pointing away from lifters. Intake specification typically 0.15-0.25mm, exhaust 0.25-0.35mm (verify exact specs in service manual). Record all measurements. If any clearances are out of specification, calculate required shim thickness and install appropriate adjustment shims.
    ⚠Incorrect valve clearance will cause poor performance, noise, or valve damage. This step cannot be skipped with new lifters.
15. 15

    Install timing cover and valve cover
    Install new timing chain cover gasket and install upper timing cover. Torque cover bolts to 16 Nm (12 lb-ft). Install new valve cover gasket ensuring proper orientation and seating in valve cover groove. Install valve cover and torque bolts to 10 Nm (7 lb-ft) in proper sequence from center outward. Install all previously removed components: ignition coils, engine mount, intake system.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)

Reassembly

1. Reinstall all electrical connectors, vacuum hoses, and breather hoses to valve cover in original positions.
2. Reinstall spark plugs to specified torque and reconnect ignition coils.
3. Reinstall engine mount and remove support jack from under engine.
4. Reinstall air intake assembly and air filter housing.
5. Reinstall engine cover.
6. Reconnect negative battery cable.
7. Fill engine with 5 quarts Toyota Genuine 0W-20 engine oil using new oil filter.

Verification

• Before starting engine, manually rotate crankshaft two complete revolutions clockwise using socket on crankshaft bolt. Verify smooth rotation with no binding or resistance.
• Verify timing marks realign perfectly after two revolutions. Any misalignment indicates timing error - do not start engine.
• Check that all tools and parts have been removed from engine compartment.
• Prime oil system by cranking engine with fuel pump fuse removed for 10 seconds (engine will not start). Repeat 2-3 times.
• Start engine and verify immediate oil pressure on gauge. If no pressure within 3 seconds, shut down immediately.
• Let engine idle and listen carefully for any unusual noises, ticking, or knocking. Any abnormal sounds indicate problem requiring immediate shutdown and inspection.
• Monitor for oil leaks around valve cover and timing cover. Minor seepage may occur initially but should not be active dripping.
• After 10 minutes warm-up, shut off engine and recheck oil level. Top off as needed.
• After 50-100 miles, recheck valve clearances as new lifters may settle slightly. Adjust if needed.
• Change engine oil and filter after 500 miles of operation with new lifters.

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