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After a lot of reading and watching videos I realize there could be several reasons for this failure which makes it hard to troubleshoot. I am not an auto mechanic but here is my list of potential reasons and some other thoughts.

Camshaft timing oil control valve
VVT-I module on end of camshaft
Intermitent wiring harness fault
intermitent ECU fault


My thought on what is causing the noise is that one (or several) of the VVT-I modules did not return to the default cam position when the engine was shut off. When the engine is started with the VVT-I(s) in this "unknown" state, the camshaft is retarded and advanced due to compression in the cylynders pushing valves shut and the VVT-I(s) is(are) slammed back and forth.

A couple related links.

http://share.qclt.com/丰田Toyota RAV4...E Engine Control System/Camshaft Timing Oil Control Valve Assembly/00600310.pdf

Problem with mine is that is doesn't happen more than once every 2 weeks. I guess that is a good thing.

I will keep watching, waiting and following this forum.
 
Any of the 2gr-fe variant engines (Toyota, Lexus)will eventually develop this kiss of death sound. It is an almost $6000 fix by the dealers. I have checked with local repair shops and no one wants to repair it.. To much time and way to risky they say.

Was told by a local shop the engine was born with cancer and eventually it will be terminal...

Toyota used the bad VVT-I gear from 2006-2010 and then changed the design of the part. It was to expensive to recall so they just upped the warranty to 5 year or 60k miles..

Best bet is to dump the car as fast as you can, especially back on another Toyota dealership so they get stuck with it and the bad design an bad support.

Read into this as you want. I am dealing with it now and Toyota says to bad. I have purchased Toyotas for the last 25 years. My relationship with Toyota is forever broken going forward...

There are TSB's on this issue for both Toyota and Lexus. I am fighting this as hard as I can with Toyota Corporate for some portion of the fix. TOY-OH-DUH used to be reliable and they have really gone down hill.
 
Well... Vehicle was in for 3 days and the noise cannot be reproduced. First start in the parking lot and it makes the noise...of course no service monkey around to hear it.

Had enough..dumping the car.
 
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