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Engine Mechanical: Mechanical: Camshaft: Replacement

  1. REMOVE TIMING BELT, see  TIMING BELT REPLACEMENT  . 
  2. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY, see  REPLACEMENT  . 
  3. PISTON & VALVE BREAK PREVENT WORK 
    1. Turn the crankshaft timing pulley counterclockwise by 45° and match the cut part with the illustrated position.
    NOTE: Positioning the No.1 cylinder at 45° BTDC does not make the valve and piston interfere with each other even when the valve is full open.
    NOTE: Be sure to match the cut part by timing it counterclockwise.
    Fig 1: Turning Crankshaft Timing Pulley Counterclockwise
    G03387598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE CAMSHAFT TIMING PULLEY 
    1. Remove the 4 bolts and timing pulley.
    Fig 2: Removing Camshaft Timing Pulley
    G03387599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 
  6. REMOVE CAMSHAFT 
    NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
    1. Boring the service bolt hole of the sub-gear upward by turning the hexagon wrench head portion of the exhaust camshaft with a wrench.
    2. Secure the sub-gear to the main gear with a service bolt.

      Recommended service bolt: 

      SERVICE BOLT SPECIFICATIONS

      Thread diameter 6 mm
      Thread pitch 1.0 mm
      Bolt length 16 - 20 mm (0.63 - 0.79 in.)
      NOTE: When removing the camshaft, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation.
      Fig 3: Securing Sub-Gear To Main Gear With Service Bolt
      G03387600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Set the timing mark (1 dot mark) of the camshaft main gear at approx. 10° angle by turning the hexagon wrench head portion of the exhaust camshaft with a wrench.
      Fig 4: Setting Camshaft Main Gear Timing Mark
      G03387601Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Uniformly loosen the 22 bearing cap bolts in several passes, in the sequence shown.
      Fig 5: Loosening Bearing Cap Bolts In Sequence
      G03387602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 22 bearing cap bolts, 4 seal washers, oil feed pipe, 9 bearing caps, camshaft housing plug, oil control valve filter and 2 camshafts.
      NOTE:
      • Do not pry the camshaft with a tool or the likes by applying excessive force to it.
      • Do not damage the reception part of the thrust in the cylinder head side.
    6. Mount the hexagon wrench head portion of the intake camshaft in a vise.
      NOTE:
      • Be careful not to damage the camshaft.
      • The 4 bolts shown in the illustration determine the backlash of the gear in the timing tube, so do not remove them. If any of the 4 bolts are removed, install a new timing tube assembly.
        • Fig 6: Identifying Bolts That Are Not To Be Removed
        G03387603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the screw plug and seal washer.
    8. Using a 10 mm hexagon wrench, and remove the bolt.
      9. Fig 7: Removing Camshaft Timing Bolt
      G03387604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Pull out the timing tube and drive gear assembly from the camshaft.
    10. Using SST and a 5 mm hexagon wrench, and remove the 4 bolts, drive gear and oil seal.
      NOTE: Be careful not to damage the timing tube.
      Fig 8: Removing Drive Gear And Oil Seal
      G03387605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09960-10010 (09962-01000, 09963-00500)

  7. INSTALL CAMSHAFT 
    1. Insert a new oil seal into the camshaft timing tube until it reaches the stopper.
      Fig 9: Inserting Oil Seal Into Camshaft Timing Tube
      G03387606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful of the installation direction.
      • Do not turn over the oil seal lip.
    2. Align the timing tube knock pin with the knock pin groove of the drive gear, and temporarily install the drive gear with the 4 bolts.
    3. Using SST and a 5 mm hexagon wrench, uniformly tighten the 4 bolts in several passes.

      SST 09960-10010 (09962-01000, 09963-00500)

      Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 

      NOTE: Be careful not to damage the timing tube.
      Fig 10: Tightening Bolts In Sequence
      G03387607Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Mount the hexagon wrench head portion of the camshaft in a vise.
      NOTE: Be careful not to damage the camshaft.
      Fig 11: Mounting Hexagon Wrench Head Portion Of Camshaft In Vise
      G03387608Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Align the camshaft knock pin with the knock pin groove of the timing tube, and push the timing tube by hand until you feel it touch the bottom.
    6. Using a 10 mm hexagon wrench, install the bolt.
      Fig 12: Installing Camshaft Timing Bolt
      G03387609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 78 N.m (790 kgf.cm, 58 ft.lbf) 

    7. Install the seal washer and screw plug.

      Torque: 15 N.m (150 kgf.cm, 11 ft.lbf) 

    8. Install the camshaft No.1 with timing tube assembly and the camshaft No.2.
      NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
      1. Apply engine oil to the cam and gear of the camshaft and also the journal of the cylinder head.
      2. Align the timing marks (1 dot mark) of the camshaft drive and driven main gears, and place the intake and exhaust camshafts.
      3. Set the timing mark (1 dot mark) of the camshaft drive and driven main gears at approx. 10° angle.
        Fig 13: Aligning Camshaft Drive And Driven Main Gears
        G03387610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Apply seal packing to the camshaft housing plug.
        • Remove the old packing (FIPG) material.
        • Apply seal packing to the housing plug.

        Seal packing: Part No. 08826-00080 or equivalent 

        Fig 14: Applying Seal Packing To Camshaft Housing Plug
        G03387611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. Install the camshaft housing plug to the cylinder head as shown in the illustration.
      6. Install the oil control valve filter to the cylinder head.
        NOTE: Be careful of the installation direction.
        Fig 15: Installing Camshaft Housing Plug To Cylinder Head
        G03387612Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      7. Apply seal packing to the front bearing cap.
        • Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the bearing cap and cylinder head.

          Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and groove.

          Thoroughly clean all components to remove all the loose material.

          Using a non-residue solvent, clean both sealing surfaces.

        • Apply seal packing to the bearing cap as shown in the illustration.
          Fig 16: Applying Seal Packing To Front Bearing Cap
          G03387613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

          Install a nozzle that has been cut to a 1.5mm (0.059 in.) opening.

          Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.

          Immediately remove nozzle from the tube and reinstall cap.

        Seal packing: Part No. 08826-00080 or equivalent 

        NOTE: Do not apply seal packing to the front bearing cap grooves.
      8. Install the front bearing cap.
        NOTE: Installing the front bearing cap will determine the thrust portion of the camshaft.
      9. Install the other bearing caps in the sequence shown with the arrow mark facing forward.
        Fig 17: Identifying Front Bearing Cap Locations
        G03387614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      10. Push in the camshaft oil seal.
        Fig 18: Inserting Camshaft Oil Seal
        G03387615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      11. Install 4 new seal washers to the bearing cap bolts (1 - 4).
      12. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts (5 - 22).
        NOTE: Do not apply engine oil under the heads of the bearing cap bolts (1 - 4).
      13. Install the oil feed pipe with the 22 bearing cap bolts.
      14. Uniformly tighten the 22 bearing cap bolts in several passes, in the sequence shown.
        Fig 19: Identifying Bearing Cap Bolts Tightening Sequence
        G03387616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Torque: 

        7.5 N.m (80 kgf.cm, 66 in.lbf) for bolts 21 and 22 

        16 N.m (160 kgf.cm, 12 ft.lbf) for others 

      15. Remove the service bolt.
        Fig 20: Removing Service Bolt
        G03387617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 
  9. INSTALL CAMSHAFT TIMING PULLEY 
    1. Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
    2. Attach the timing pulley to the camshaft timing tube, facing the "R" mark forward.
      Fig 21: Installing Camshaft Timing Pulley
      G03387618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Hold the hexagon wrench head portion of the camshaft, install the 4 pulley bolts.

      Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 

  10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY, see  REPLACEMENT  . 
  11. INSTALL TIMING BELT, see  TIMING BELT REPLACEMENT  . 
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