This procedure adjusts valve lash clearance on the 2019-2024 Toyota RAV4 2.5L I4 engine to ensure proper valve train operation and engine performance.

Warnings

Tools required

Parts

• Valve cover gasket × 1 — Use OEM specification
• Valve cover bolt grommets × 1 — Use OEM specification
• Spark plug tube seals × 4 — Use OEM specification

Fluids

• Toyota Genuine 0W-20 Engine Oil — 0.5 qt

Preparation

1. Ensure engine is completely cold (at ambient temperature for at least 3 hours)
2. Disconnect negative battery terminal and wait 90 seconds for airbag system to discharge
3. Remove engine cover by pulling upward on front and rear clips
4. Remove air intake duct and air filter housing to access valve cover
5. Disconnect ignition coil connectors and remove all four ignition coils
6. Label and disconnect any hoses, wiring harnesses, or brackets attached to valve cover
7. Have a clean workspace ready for valve cover to prevent contamination

Procedure

1. 1

   Remove valve cover
   Remove valve cover bolts in reverse of tightening sequence (working from outside to inside). Carefully lift valve cover off, tapping gently with rubber mallet if stuck. Inspect and clean mating surfaces thoroughly.
   Torque spec

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

   Position crankshaft to TDC cylinder 1
   Rotate crankshaft clockwise using crankshaft pulley bolt until timing marks on camshaft gears align with their marks on the cylinder head. Verify cylinder 1 is at TDC compression stroke (both intake and exhaust cam lobes pointing away from valves).
   ⚠Only rotate engine in clockwise direction when viewed from front of vehicle.
3. 3

   Check valve lash on first set of valves
   With cylinder 1 at TDC, check valve lash on cylinders 1 and 3. Insert appropriate feeler gauge between camshaft lobe base circle and valve lifter. Gauge should slide with slight resistance. Record measurements for intake valves (0.18-0.22mm specification) and exhaust valves (0.28-0.32mm specification).
   ℹ️Measure only when camshaft lobe is on base circle (pointing away from valve). Incorrect measurement position will give false readings.
4. 4

   Rotate crankshaft 360 degrees
   Rotate crankshaft clockwise exactly 360 degrees (one full revolution) to position cylinders 2 and 4 for valve lash measurement. Verify camshaft timing marks have rotated one full turn.
5. 5

   Check valve lash on remaining valves
   Check and record valve lash measurements for cylinders 2 and 4 using the same feeler gauge technique. Compare all recorded measurements against specifications to identify which valves require adjustment.
6. 6

   Adjust out-of-specification valves
   For each valve requiring adjustment, loosen the valve lash adjusting screw lock nut while holding the adjusting screw with appropriate tool. Turn adjusting screw clockwise to decrease clearance or counterclockwise to increase clearance. Recheck clearance with feeler gauge and repeat until within specification.
   ⚠Always hold adjusting screw firmly while tightening lock nut to prevent screw from turning and changing adjustment.
   Torque spec

   Valve Lash Adjusting Screw Lock Nut20 Nm (15 lb-ft)
7. 7

   Verify all adjustments
   After completing all adjustments, rotate crankshaft two complete revolutions and recheck all valve lash measurements to confirm they remain within specification. Readjust any valves that have shifted out of tolerance.
8. 8

   Clean and inspect valve cover components
   Remove old gasket material from valve cover and cylinder head mating surfaces using plastic scraper. Clean surfaces with parts cleaner and lint-free cloth. Inspect valve cover for cracks or warping. Replace spark plug tube seals and valve cover bolt grommets.
   ⚠Do not use metal scrapers on aluminum mating surfaces as this can cause damage and oil leaks.
9. 9

   Install new valve cover gasket
   Install new valve cover gasket and spark plug tube seals. Ensure gasket is properly seated in valve cover groove with no twists or gaps. Apply thin coat of clean engine oil to gasket before installation.
10. 10

    Reinstall valve cover
    Position valve cover carefully onto cylinder head, ensuring gasket stays in place and all bolt holes align. Install valve cover bolts with new grommets finger-tight initially. Torque bolts in proper sequence (center outward) to specification in multiple passes.
    ℹ️Tightening sequence: start from center bolts and work outward in a cross pattern. First pass to 5 Nm, final pass to 10 Nm.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)

Reassembly

1. Reinstall ignition coils and torque to specification, reconnect electrical connectors
2. Reinstall all hoses, wiring harnesses, and brackets to valve cover area
3. Reinstall air filter housing and intake duct with all clamps secure
4. Reinstall engine cover by pressing down firmly on mounting points until clips engage
5. Reconnect negative battery terminal
6. Reset any necessary vehicle systems after battery reconnection

Verification

• Start engine and verify no oil leaks from valve cover, particularly around bolt areas and spark plug tubes
• Listen for abnormal valve train noise; properly adjusted valves should operate quietly
• Allow engine to reach operating temperature and recheck for leaks
• Check for diagnostic trouble codes related to ignition or camshaft position sensors
• Test drive vehicle to verify smooth operation and proper engine performance

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