A25A-FXS (ENGINE MECHANICAL): CAMSHAFT: REMOVAL; 2023 - 2024 MY RAV4 HV [10/2022

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM10000000289CJ
Model Year Start: 2023	Model: RAV4 HV	Prod Date Range: [10/2022 - ]
Title: A25A-FXS (ENGINE MECHANICAL): CAMSHAFT: REMOVAL; 2023 - 2024 MY RAV4 HV [10/2022 - ]

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during camshaft removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
Replacement of fuel pump assembly (for high pressure side) Replacement of ignition coil assembly Replacement of throttle body with motor assembly Cleaning the deposits from the throttle body with motor assembly Gas leak from exhaust system is repaired Replacement of cam timing control motor with EDU assembly Replacement of camshaft timing gear assembly Replacement of camshaft (for intake or exhaust camshaft) Replacement of camshaft timing exhaust gear assembly Removal and installation of a cam timing control motor with EDU assembly Removal and installation of a camshaft timing gear assembly	Inspection after repair	Poor idle, etc. Engine start function, etc.

NOTICE:

After the ignition switch is turned off, the audio and visual system records various types of memory and settings. As a result, after turning the ignition switch off, make sure to wait at least 2 minutes before disconnecting the cable from the negative (-) auxiliary battery terminal.
When the cable is disconnected from the negative (-) auxiliary battery terminal and the security lock setting has been enabled, multi-display operations will be disabled upon next startup unless the password is entered. Be sure to check the security lock setting before disconnecting the cable from the negative (-) auxiliary battery terminal.
This procedure includes the removal of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.
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PROCEDURE

1. REMOVE FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)

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2. DISCONNECT ENGINE WIRE

(a) Disconnect the 6 connectors.

(b) Detach the 3 clamps and disconnect the engine wire.

3. REMOVE IGNITION COIL ASSEMBLY

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4. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side)

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5. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side)

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6. REMOVE CAM TIMING OIL CONTROL SOLENOID ASSEMBLY

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7. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (EXHAUST CAMSHAFT TIMING GEAR BOLT ASSEMBLY)

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8. REMOVE CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY

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9. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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10. REMOVE SPARK PLUG TUBE GASKET

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11. REMOVE FUEL PUMP LIFTER GUIDE

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12. SET NO. 1 CYLINDER TO TDC (COMPRESSION)

(a) Turn the crankshaft clockwise to align the timing mark (cutout) on the crankshaft pulley with the "0" timing mark on the No. 2 timing chain cover assembly.

*a	Paint Mark
*b	Timing Mark
*c	"0" Timing Mark

(b) Check that the timing marks are positioned as shown in the illustration.

HINT:

If the timing marks are not positioned as shown in the illustration, turn the crankshaft clockwise and then align them again.

(c) Place paint marks on the timing chain sub-assembly at points aligned with the timing marks on the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

13. REMOVE STRAIGHT SCREW PLUG

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14. REMOVE CAMSHAFT

(a) Rotate the crankshaft approximately 15° clockwise.

*a	Approximately 15°

(b) Rotate the crankshaft approximately 15° counterclockwise.

*a	Approximately 15°

(c) Align the pin hole of the No. 1 chain tensioner assembly with the pin hole of the chain tensioner slipper, and then insert the pin.

*a	Pin
*b	Pin Hole (No. 1 Chain Tensioner Assembly Side)
*c	Pin Hole (Chain Tensioner Slipper Side)

(d) Using the hexagonal portion of the No. 2 camshaft, secure the No. 2 camshaft.

NOTICE:

Do not damage the camshaft housing sub-assembly, cylinder head sub-assembly and spark plug tube.

Hold

(e) Remove the 2 bolts from the camshaft timing exhaust gear assembly.

(f) Using the hexagonal portion of the camshaft, secure the camshaft.

*a	Hold
	Turn

NOTICE:

Do not damage the camshaft housing sub-assembly, cylinder head sub-assembly and spark plug tube.
Do not disassemble the camshaft timing gear assembly.

(g) Using a bi-hexagon socket wrench (10 mm), remove the bolt from the camshaft timing gear assembly.

(h) Using the hexagonal portion of the No. 2 camshaft, loosen and hold the timing chain sub-assembly while moving the No. 2 camshaft in the direction shown in the illustration.

*a	Hold	-	-
	Turn	-	-

(i) Move the camshaft timing gear assembly together with the camshaft timing exhaust gear assembly and timing chain sub-assembly toward the No. 2 timing chain cover assembly as shown in the illustration.

*1	Camshaft Timing Gear Assembly	*2	Camshaft Timing Exhaust Gear Assembly
*3	Timing Chain Sub-assembly	-	-
	Remove in this Direction	-	-

(j) Remove the camshaft timing exhaust gear assembly from the timing chain sub-assembly.

(k) Remove the camshaft timing gear assembly from the timing chain sub-assembly.

(l) Secure the timing chain sub-assembly to the vehicle using rope, etc.

NOTICE:

Do not drop the timing chain sub-assembly into the timing chain cover assembly.

(m) Uniformly loosen and remove the 8 camshaft bearing cap bolts in the order shown in the illustration.

(n) Uniformly loosen and remove the 14 camshaft bearing cap bolts in the order shown in the illustration.

NOTICE:

Uniformly loosen the camshaft bearing cap bolts while holding the camshaft horizontally.

*1	No. 1 Camshaft Bearing Cap
*2	No. 2 Camshaft Bearing Cap
*3	No. 3 Camshaft Bearing Cap
*4	No. 4 Camshaft Bearing Cap

(o) Remove the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, 2 No. 3 camshaft bearing caps and No. 4 camshaft bearing cap.

HINT:

Arrange the removed parts so that they can be reinstalled in their original locations.

(p) Remove the camshaft from the camshaft housing sub-assembly.

(q) Remove the No. 2 camshaft from the camshaft housing sub-assembly.