Toyota RAV4 > Engine > Camshafts, camshaft housing, rocker arms and lash adjusters — removal, inspection and installation

Camshafts, camshaft housing, rocker arms and lash adjusters — removal, inspection and installation

Caution: The camshafts should always be thoroughly inspected before installation, and camshaft endplay should always be checked prior to camshaft removal (see Step 20).

Removal

1. Disconnect the cable from the negative battery terminal (see Engine electrical systems).

2. Remove the engine.

3. Remove the valve cover (see Valve cover — removal and installation ). then refer to Top Dead Center (TDC) for number one piston — locating and place the engine at TDC for number 1 cylinder. Visually confirm the engine is at TDC on the compression stroke by verifying that the timing mark on the crankshaft pulley/vibration damper is aligned with the «0» mark on the timing chain cover and the camshaft sprocket TDC marks are aligned and parallel with the top of the timing chain cover (see illustrations 3.8 and 6.1).

4. With the TDC marks aligned, apply a dab of paint to the timing chain links where they meet the upper timing marks on the camshaft sprockets.

5. Using a wrench to hold the camshaft sprockets from turning, loosen the camshaft sprocket bolts several turns (see illustration 6.12).

6. Remove the timing chain cover and tensioner (see Timing chain and sprockets — removal, inspection and installation …. ).

7. Remove the camshaft sprocket retaining bolts. Disengage the timing chain from the sprockets and remove the camshaft sprockets from the engine. Make sure to note that the Variable Valve Timing (VVT) actuator is installed on the intake camshaft and the exhaust camshaft. Also place a rag in the opening of the timing chain cover to prevent any foreign objects from falling into the engine (see illustration).

i. 7 With the camshaft sprockets removed, hang the timing chain out of the way with a piece of wire and place a shop rag in the timing chain cover opening to prevent foreign objects from falling into the engine

Toyota RAV4 Engine | Camshafts, camshaft housing, rocker arms and lash adjusters - removal, inspection and installation _ With the camshaft sprockets removed, hang the timing chain out of the way with a piece of wire and place a shop rag in the timing chain cover opening to prevent foreign objects from falling into the engine

8. Loosen the camshaft housing bearing cap bolts in sequence in two or three steps, in the reverse order of the tightening sequence (see illustration .30).

9. Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.

Note: Be careful not to damage the cylinder head and camshaft housing.

10. Loosen the camshaft bearing cap bolts in sequence in two or three steps, in the reverse order of the tightening sequence (see illustrations 7.26).

11. Remove the bearing caps, if necessary the bearing inserts from the No.1 bearing cap, oil control filter and camshafts from the camshaft housing.

Note: The Number 1 bearing cap has bearing inserts that can be replaced, make sure to keep them in order and install them into their original locations.

12. Remove the rocker arms from the cylinder head.

Caution: Keep the rocker arms in order. They must go back in the position from which they were removed.

13. Remove the lash adjusters from the cylinder head.

Caution: Keep the lash adjusters in order. They must go back in their original positions.

14. Inspect the camshafts, camshaft bearings, camshaft housing, rockers and lash adjusters as described below. Also inspect the camshaft sprockets for wear on the teeth. Inspect the chains for cracks or excessive wear of the rollers, and for stretching (see Timing chain and sprockets — removal, inspection and installation …. ). If any of the components show signs of excessive wear, they must be replaced.

 

Inspection

15. Before the camshafts are removed from the engine, check the camshaft endplay by placing a dial indicator with the stem in line with the camshaft and touching the snout (see illustration). Push the camshaft all the way to the rear and zero the dial indicator. Next, pry the camshaft to the front as far as possible and check the reading on the dial indicator. The distance it moves is the endplay. If the endplay for the intake camshaft is greater than the Specifications listed in this Chapter, check the thrust surfaces of the No.1 journal bearing for wear. If the thrust surface is worn, the bearings must be replaced. If the endplay for the exhaust camshaft is greater than the Specifications listed in this Chapter, the camshaft or the cylinder head (or both) may need to be replacedё

i. 15 Mount a dial indicator as shown to measure camshaft endplay — pry the camshaft forward and back and read the endplay on the dial

Toyota RAV4 Engine | Camshafts, camshaft housing, rocker arms and lash adjusters - removal, inspection and installation _ Mount a dial indicator as shown to measure camshaft endplay - pry the camshaft forward and back and read the endplay on the dial

16. With the camshafts removed, visually check the camshaft bearing surfaces in the cylinder head for pitting, score marks, galling and abnormal wear. If the camshaft housings or camshafts bearing surfaces are damaged, or the No.1 journal bearings may have to be replaced (see illustration).

i. 16 Inspect the No. 2 through No. 5 cam bearing surfaces in the camshaft housing for pits, score marks and abnormal wear — if wear or damage is noted, the camshaft housing must be replaced

Toyota RAV4 Engine | Camshafts, camshaft housing, rocker arms and lash adjusters - removal, inspection and installation _ Inspect the No. 2 through No. 5 cam bearing surfaces in the camshaft housing for pits, score marks and abnormal wear - if wear or damage is noted, the camshaft housing must be replaced

17. Measure the outside diameter of each camshaft bearing journal and record your measurements (see illustration). Compare them to the journal outside diameter as specified in this Chapter’s Specifications, then measure the inside diameter of each corresponding camshaft bearing and record the measurements. Subtract each cam journal outside diameter from its respective cam bearing bore inside diameter to determine the oil clearance for each bearing. Compare the results to the specified journal-to-bearing clearance. If any of the measurements fall outside the standard specified wear limits in this Chapter’s Specifications, either the camshaft or the camshaft housing, or both, must be replaced.

i. 17 Measure each journal diameter with a micrometer — if any journal measures less than the specified limit, replace the camshaft

Toyota RAV4 Engine | Camshafts, camshaft housing, rocker arms and lash adjusters - removal, inspection and installation _ Measure each journal diameter with a micrometer - if any journal measures less than the specified limit, replace the camshaft

Note: If precision measuring tools are not available, Pasturage may be used to determine the bearing journal oil clearance.

18. Using a micrometer, measure the height of each camshaft lobe (see illustration). Compare your measurements with this Chapter’s Specifications. If the height for any one lobe is less than the specified minimum, replace the camshaft.

i. 18 Measure the lobe heights on each camshaft — if any lobe height is less than the specified allowable minimum, replace that camshaft

Toyota RAV4 Engine | Camshafts, camshaft housing, rocker arms and lash adjusters - removal, inspection and installation _ Measure the lobe heights on each camshaft - if any lobe height is less than the specified allowable minimum, replace that camshaft

19. Check the camshaft runout by placing the camshaft back into the cylinder head and set up a dial indicator on the center journal. Zero the dial indicator. Turn the camshaft slowly and note the dial indicator readings. Runout should not exceed 0.0012 inch (0.03 mm). If the measured runout exceeds the specified runout, replace the camshaft.

20. Inspect the rocker arms and lash adjusters for scuffing and score marks (see illustration).

i. 20 Check the rocker arms and lash adjusters for wear at the indicated points

Toyota RAV4 Engine | Camshafts, camshaft housing, rocker arms and lash adjusters - removal, inspection and installation _ Check the rocker arms and lash adjusters for wear at the indicated points

Installation

21. Coat the lash adjusters with engine oil and install them into the cylinder head in the same locations from which they were removed.

22. Apply oil to the rocker arms and install them, making sure they are seated to their lash adjusters.

23. Install the camshaft bearings into the camshaft housing.

24. Apply camshaft installation lubricant to the camshaft lobes and journals and install the camshaft into the camshaft housing.

25. Install oil control valve filter into the No.1 bearing cap, then install the camshaft bearing caps and tighten the bearing cap bolts in several equal steps, to the torque listed in this Chapter’s Specifications, using the proper tightening sequence (see illustration).

i. 25 Camshaft bearing cap bolt TIGHTENING sequence

Toyota RAV4 Engine | Camshafts, camshaft housing, rocker arms and lash adjusters - removal, inspection and installation _ Camshaft bearing cap bolt TIGHTENING sequence

26. Check that the rocker arms are installed properly and have not moved.

27. Position the dowel pins facing upwards; the intake camshaft dowel pin should be at a 17-degree angle and the exhaust pin should be at a 2-degree angle (counterclockwise from the 12 o’clock position).

28. Clean the camshaft housing mounting surface. Apply a 1/4-inch wide bead of Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent to the camshaft housing-to-cylinder head contact surface.

Note: The camshaft housing must be installed within 3 minutes and the bolts tightened within 10 minutes after applying seal packing.

29. Install the camshaft housing to the cylinder head, install the mounting bolts and tighten the bolts in several equal steps, to the torque listed in this Chapter’s Specifications, using the proper tightening sequence (see illustration).

i. 29 Camshaft housing bolt TIGHTENING sequence

Toyota RAV4 Engine | Camshafts, camshaft housing, rocker arms and lash adjusters - removal, inspection and installation _ Camshaft housing bolt TIGHTENING sequence

Caution: Do not add oil or try to start the engine for at least 4 hours after installation or the seal packing will leak.

30. Install the camshaft sprockets, timing chain and timing chain cover (see Timing chain and sprockets — removal, inspection and installation …. ).

31. The remainder of installation is the reverse of removal.

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