Toyota RAV4 2000-05

Camshaft, Bearings & Lifters 1

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Inspection



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the camshaft from the engine.
  4.  
  5. Check the camshaft bearing journals for damage and binding.
  6.  
  7. If the journals are binding, check the cylinder head for damage.
  8.  
  9. Check the cylinder head for clogged oil holes.
  10.  
  11. Check the camshaft surface for abnormal wear and damage. Replace the camshaft, as required.
  12.  
  13. Measure the camshaft lobe surface and replace the camshaft if not within specification.
  14.  
  15. Measure the camshaft journal diameter and replace the camshaft if not within specification.
  16.  
  17. Measure the camshaft run out and replace the camshaft if not within specification.
  18.  

Removal & Installation



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Cylinder head cover and the upper timing belt cover
     

  4.  
  5. Rotate the crankshaft to set the engine at Top Dead Center (TDC)/compression for the No. 1 cylinder.
    NOTE
    Due to the small thrust clearance on both the intake and exhaust camshafts, the camshafts must be kept level during removal. If the camshafts are removed without being kept level, the camshaft may be caught in the cylinder head causing the head to break or the camshaft to seize.

  6.  
  7. Remove the camshaft timing sprocket and the timing belt.
  8.  
  9. Set the knock pin of the intake camshaft at 10-45 degrees Before Top Dead Center (BTDC) of camshaft angle. This angle will help to lift the exhaust camshaft level and evenly by pushing No. 2 and No. 4 cylinder camshaft lobes of the exhaust camshaft toward their valve lifters.
  10.  
  11. Secure the exhaust camshaft sub-gear to the main gear using a service bolt. The manufacturer recommends a bolt 0.63-0.79 in. (16-20mm) long with a thread diameter of 6mm and a 1mm thread pitch. When removing the exhaust camshaft, be sure that the torsional spring force of the sub-gear has been eliminated.

    Click image to see an enlarged view

    Fig. Exhaust camshaft bolt removal: Step 1-RAV4 2.0L



    Click image to see an enlarged view

    Fig. Exhaust camshaft bolt removal: Step 2-RAV4 2.0L

  12.  
  13. Remove the No. 1 and No. 2 rear bearing cap bolts and remove the cap. Uniformly loosen and remove bearing cap bolts No. 3 to No. 8 in several passes and in the proper sequence. Do not remove bearing cap bolts No. 9 and 10 at this time. Remove the No. 1, 2 and 4 bearing caps.

    Click image to see an enlarged view

    Fig. Exhaust camshaft bolt removal: Step 3-RAV4 2.0L

  14.  
  15. Alternately loosen and remove bearing cap bolts No. 9 and 10. As these bolts are loosened check to see that the camshaft is being lifted out straight and level.
    NOTE
    If the camshaft is not lifting out straight and level retighten No. 9 and 10 bearing cap bolts. Reverse the order of Steps 5 through 7 and reset the intake camshaft knock pin to 10-45 degrees BTDC and repeat Steps 5 through 7 again. Do not attempt to pry the camshaft from its mounting.

  16.  
  17. Remove the No. 3 bearing cap and exhaust camshaft from the engine.
  18.  
  19. Set the knock pin of the intake camshaft at 80-115 degrees BTDC of camshaft angle. This angle will help to lift the intake camshaft level and evenly by pushing No. 1 and No. 3 cylinder camshaft lobes of the intake camshaft toward their valve lifters.

    Click image to see an enlarged view

    Fig. Intake camshaft knock pin alignment-RAV4 2.0L

  20.  
  21. Remove the No. 1 and No. 2 front bearing cap bolts and remove the front bearing cap and oil seal. If the cap will not come apart easily, leave it in place without the bolts.

    Click image to see an enlarged view

    Fig. Intake camshaft bolt removal: Step 1-RAV4 2.0L

  22.  
  23. Uniformly loosen and remove bearing cap bolts No. 3 to No. 8 in several phases and in the proper sequence. Do not remove bearing cap bolts No. 9 and 10 at this time. Remove No. 1, 3 and 4 bearing caps.

    Click image to see an enlarged view

    Fig. Intake camshaft bolt removal: Step 2-RAV4 2.0L

  24.  
  25. Alternately loosen and remove bearing cap bolts No. 9 and 10. As these bolts are loosened and after breaking the adhesion on the front bearing cap, check to see that the camshaft is being lifted out straight and level.
    NOTE
    If the camshaft is not lifting out straight and level retighten No. 9 and 10 bearing cap bolts. Reverse steps 10 through 12, than start over from Step 10. Do not attempt to pry the camshaft from its mounting.

  26.  
  27. Remove the No. 2 bearing cap with the intake camshaft from the engine.

    Click image to see an enlarged view

    Fig. Intake camshaft bolt removal: Step 3-RAV4 2.0L

  28.  
  29. Remove the valve adjusting shims from the engine. Be sure to replace the shims to their original location.
  30.  

To install:

  1. Install the valve adjusting shims to the engine.
  2.  
  3. Before installing the intake camshaft, apply multi-purpose grease to the thrust portion of the camshaft.
  4.  
  5. Position the camshaft at 80-115 degrees BTDC of camshaft angle on the cylinder head.
  6.  
  7. Apply sealant to the front bearing cap.

    Click image to see an enlarged view

    Fig. Intake camshaft bearing cap positioning-RAV4 2.0L

  8.  
  9. Coat the bearing cap bolts with clean engine oil.
  10.  
  11. Tighten the camshaft bearing caps evenly and in several passes to 14 ft. lbs. (19 Nm) in the proper sequence.

    Click image to see an enlarged view

    Fig. Intake camshaft bolt tightening sequence-RAV4 2.0L

  12.  
  13. Set the knock pin of the camshaft at 10-45 degrees BTDC of camshaft angle.
  14.  
  15. Apply multipurpose grease to the thrust portion of the camshaft.
  16.  
  17. Position the exhaust camshaft gear with the intake camshaft gear so that the timing marks are in alignment with one another. Be sure to use the proper alignment marks on the gears. Do not use the assembly reference marks.

    Click image to see an enlarged view

    Fig. Camshaft timing mark alignment-RAV4 2.0L

  18.  
  19. Turn the intake camshaft clockwise or counterclockwise little by little until the exhaust camshaft sits in the bearing journals evenly without rocking the camshaft on the bearing journals.

    Click image to see an enlarged view

    Fig. Exhaust camshaft bearing cap positioning-RAV4 2.0L

  20.  
  21. Coat the bearing cap bolts with clean engine oil.
  22.  
  23. Tighten the camshaft bearing caps evenly and in several passes to 14 ft. lbs. (19 Nm). Remove the service bolt from the assembly.

    Click image to see an enlarged view

    Fig. Exhaust camshaft bolt tightening sequence-RAV4 2.0L



    Click image to see an enlarged view

    Fig. Exhaust camshaft knock pin alignment-RAV4 2.0L

  24.  
  25. Install the camshaft timing pulleys and the timing belt.
  26.  
  27. Adjust the valve clearance.
  28.  
  29. Install the head cover and the upper timing cover. Reconnect the negative battery cable.
  30.  
  31. Start the engine and check for leaks.
  32.  
  33. Check and adjust the ignition timing.
  34.  

 
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