Complete removal and replacement of all valve springs on the 2019-2024 Toyota RAV4 2.5L I4 engine, requiring camshaft removal and valve train disassembly.

Warnings

Tools required

Parts

• Valve springs (set of 16) × 1 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Camshaft cap gasket/sealant × 1 — Toyota Genuine FIPG 1281 or equivalent
• Spark plug tube seals × 4 — Use OEM specification
• PCV valve grommet × 1 — Use OEM specification
• Anti-seize compound × 1 — Nickel-based for aluminum heads

Fluids

• Toyota Genuine 0W-20 engine oil — 5 qt

Preparation

1. Ensure engine is completely cold (at least 2 hours after last operation)
2. Disconnect negative battery terminal and wait 90 seconds for airbag system discharge
3. Remove engine cover by pulling upward on front edge
4. Remove air intake system from air filter box to throttle body
5. Disconnect ignition coil connectors and remove all four ignition coils
6. Label and photograph all vacuum hoses, electrical connections, and breather hoses connected to valve cover
7. Disconnect PCV hose and all breather hoses from valve cover
8. Position drain pan and prepare workspace with clean towels to place components

Procedure

1. 1

   Remove spark plugs and valve cover
   Remove all four spark plugs and set aside. Remove valve cover bolts in reverse of tightening sequence (outside to inside pattern). Carefully lift valve cover off, tapping gently with rubber mallet if stuck. Inspect valve cover gasket and spark plug tube seals for damage.
   Torque spec

   Spark Plugs - Aluminum Head20 Nm (15 lb-ft)
2. 2

   Rotate engine to TDC cylinder #1
   Rotate crankshaft clockwise using 19mm socket on crankshaft pulley bolt until timing marks on camshaft sprockets align with their corresponding marks on the timing chain cover. Verify #1 cylinder is at top dead center compression stroke. Mark the position of timing chain to camshaft sprockets with paint pen for reassembly reference.
   ⚠Take multiple photos of timing chain position and alignment marks. Incorrect timing will prevent engine from running.
3. 3

   Mark and remove camshaft bearing caps
   Using paint pen or stamping tool, clearly mark each camshaft bearing cap with its position number and orientation arrow pointing toward front of engine. Number caps 1-5 on intake camshaft and 1-5 on exhaust camshaft. Loosen camshaft cap bolts in multiple passes, working from outer caps toward center in 1/4 turn increments to gradually release valve spring tension.
   ⚠️Caps must be loosened gradually and evenly. Sudden release can bend camshafts or damage caps due to valve spring pressure.
   Torque spec

   Camshaft Cap Bolts14 Nm (10 lb-ft)
4. 4

   Remove camshafts and timing chain
   Once all cap bolts are removed, carefully lift bearing caps and store in order. Note the location of dowel pins in caps. Lift both camshafts straight up and out, keeping timing chain secured to sprockets with wire or zip ties. Support timing chain with wire to prevent it from falling into timing chain case. Place camshafts on clean surface with lobes facing up.
   ⚠Do not allow timing chain to fall into timing cover. Secure chain with mechanic wire to prevent misalignment.
5. 5

   Remove rocker arms and lash adjusters
   Remove all 16 rocker arms and hydraulic lash adjusters, keeping them in exact order. Use a numbered container or egg carton labeled 1-16 corresponding to valve positions. Inspect rocker arm contact surfaces and lash adjuster condition. Lash adjusters must be stored upright to prevent oil from draining out.
   ℹ️Rocker arms and lash adjusters must be reinstalled in their exact original positions to maintain proper wear patterns.
6. 6

   Compress and remove valve springs
   Install overhead cam valve spring compressor tool on first valve. Compress spring carefully until valve keepers (collets) are accessible. Use magnetic tool to carefully remove both valve keepers and place in labeled container. Slowly release spring compressor and remove spring retainer, valve spring, and spring seat. Note the installed height and any shims present. Repeat for all 16 valves, keeping all components organized by valve number.
   ⚠️Ensure valve spring compressor is properly seated before applying pressure. Tool slippage can cause spring to release violently.
   ⚠Valve keepers are tapered and must be installed with correct orientation. Mark their position before removal.
7. 7

   Inspect valves and seats
   With springs removed, inspect each valve stem for wear, scoring, or damage. Check valve stem seals for deterioration. Inspect valve seats in cylinder head for pitting or burning. Measure valve stem height protrusion if dial indicator is available. This is the ideal time to perform valve seal replacement or valve lapping if needed.
   ℹ️If valve stem seals show wear, this is the optimal time to replace them as valve springs are already removed.
8. 8

   Install new valve springs
   Install new valve spring seat (or reuse if in good condition), then new valve spring with closer-wound coils toward cylinder head (check spring orientation in service manual). Install spring retainer on top. Using valve spring compressor, compress new spring until retainer groove is accessible. Carefully install both valve keepers in groove using magnetic tool, ensuring they are fully seated in valve stem groove. Slowly release compressor and verify keepers are locked in place. Repeat for all 16 valves.
   ⚠️Verify valve keepers are fully seated before releasing spring compressor. Improperly seated keepers will cause valve to drop into cylinder.
   ⚠New springs may have different installed height than old springs. Verify installed height is within specification.
9. 9

   Reinstall lash adjusters and rocker arms
   Install each hydraulic lash adjuster back into its original bore in the cylinder head. Install each rocker arm onto its original valve and lash adjuster position, ensuring rocker arm seats properly on both valve stem and lash adjuster. Verify rocker arms move freely and are not binding.
   Torque spec

   Rocker Arm Bolts30 Nm (22 lb-ft)
10. 10

    Reinstall camshafts and timing chain
    Apply clean engine oil to all camshaft journals and lobes. Carefully lower both camshafts into position, ensuring timing chain remains on sprockets with paint marks aligned. Verify camshaft timing marks still align with marks on timing cover. Ensure all cam lobes are in correct position relative to rocker arms.
    ⚠Double-check timing chain alignment before installing bearing caps. Incorrect timing requires complete timing chain procedure to correct.
11. 11

    Install camshaft bearing caps
    Apply small amount of clean engine oil to bearing cap surfaces. Install all bearing caps in their exact original positions with orientation marks pointing forward. Install cap bolts finger-tight. Tighten camshaft cap bolts in multiple passes (3-4 passes) working from center caps outward, following factory tightening sequence. Final pass to full torque specification of 14.0 Nm (10.0 lb-ft).
    ⚠Caps must be tightened in sequence and multiple passes. Uneven tightening will damage camshaft journals.
    Torque spec

    Camshaft Cap Bolts14 Nm (10 lb-ft)
12. 12

    Verify camshaft rotation and valve clearance
    Manually rotate crankshaft two complete revolutions clockwise and verify timing marks realign correctly. Check that all rocker arms are functioning and contacting valve stems properly. Listen and feel for any binding or unusual resistance. If valve clearance inspection is required per service interval, perform inspection now before reinstalling valve cover.
    ⚠If engine does not rotate smoothly or timing marks do not realign, stop immediately and verify valve spring installation and timing chain position.
13. 13

    Clean and prepare valve cover
    Thoroughly clean valve cover mating surface and cylinder head mating surface using plastic scraper. Remove all old gasket material and oil residue. Clean spark plug tube areas. Install new spark plug tube seals into valve cover. Install new valve cover gasket onto valve cover, ensuring it seats properly in groove.
    ℹ️Do not use metal scrapers on aluminum surfaces. Scratches can cause oil leaks.
14. 14

    Install valve cover and spark plugs
    Carefully position valve cover onto cylinder head, ensuring gasket remains in place and spark plug tube seals align with their bores. Install valve cover bolts and tighten in sequence from center outward to 10.0 Nm (7.0 lb-ft). Apply anti-seize compound to spark plug threads. Install spark plugs and torque to 20.0 Nm (15.0 lb-ft).
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)

    Spark Plugs - Aluminum Head20 Nm (15 lb-ft)
15. 15

    Reinstall ignition system and accessories
    Install all four ignition coils and torque mounting bolts to specification. Reconnect ignition coil electrical connectors. Reconnect all vacuum hoses, breather hoses, and PCV valve to valve cover per photographs taken during disassembly. Install air intake system. Install engine cover. Reconnect battery negative terminal.
    Torque spec

    Mounting Bolts47 Nm (35 lb-ft)

Reassembly

1. All fasteners must be torqued to specification in the correct sequence
2. Verify timing chain alignment marks match before final assembly
3. Ensure all electrical connectors and vacuum hoses are properly reconnected
4. Double-check that no tools or parts are left in engine bay

Verification

• Check engine oil level and top off to proper level with Toyota Genuine 0W-20 oil
• Start engine and verify it runs smoothly without unusual valve train noise
• Listen for valve tick or tapping that may indicate improperly seated valve keepers or rocker arm issues
• Allow engine to reach operating temperature and verify no oil leaks from valve cover
• Perform test drive and verify normal engine performance and power delivery
• Re-check valve cover bolts after first heat cycle and verify torque specification
• Monitor oil consumption over first 500 miles to ensure valve stem seals are seating properly

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