Toyota 13501-28040
Camshaft

The camshaft replacement procedure starts with disconnecting the negative battery terminal followed by unfastening the right-hand front wheel and both RH and LH engine under covers and front fender apron seal RH and engine cover sub-assembly No.1. The procedure starts by removing the fan and generator V-belt using Special Service Tool: 09249-63010 followed by separating the vane pump assembly to enable the removal of the engine mounting insulator RH along with ignition coil assembly and cylinder head cover sub-assembly. Start by setting the No. 1 cylinder at TDC/compression position before proceeding to remove the No. 2 camshaft by noting down the chain and camshaft timing gears then eliminating the bolt, releasing the wire harness protector clamp and removing its two nuts, chain tensioner and gasket while preserving the crankshaft from rotating when the chain tensioner is detached. Remove the 10 bearing cap bolts from their specified order before taking away the 5 bearing caps along with the camshaft timing gear. To work on the camshaft timing gear assembly users should place the camshaft in a vise and tape oil ports while applying air pressure to the oil path before spinning the camshaft timing gear counterclockwise. Unscrew the fringe bolt on the camshaft timing gear but keep all other 4 bolts secured. The installation process of the camshaft timing gear assembly should start by aligning it to the straight pin off the key groove then rotating it counter-clockwise with manual pressure on the camshaft while ensuring no space exists between the gear fringe and camshaft before torquing the fringe bolt to 54 Nm (551 kgf-cm, 40 ft. lbs.). Apply engine oil to the camshaft journal before alignment with the timing gear and timing chain installation. The bearing caps get installation with engine oil residue on threads and bolt heads following a specific sequence while tightened to 29.5 Nm (301 kgf-cm, 22 ft. lbs.) for No.1 cap and 9.0 Nm (92 kgf-cm, 80 inch lbs.) for No.3 cap. When installing the No. 2 camshaft you must lubricate the journal portion with engine oil before aligning the paint mark with the timing mark while temporarily tightening the camshaft timing gear set bolt and then installing the bearing caps which should be lubricated with engine oil on threads and bolt heads using the specified torque values of 29.5 Nm (301 kgf-cm, 22 ft. lbs.) for bearing cap No. 2 and 9.0 Nm (92 kgf-cm, 80 inch lbs.) for bearing cap No. 3. The process includes paint mark misalignment and crankshaft pulley groove "0" alignment with a torque setting of 54 Nm (551 kgf-cm, 40 ft. lbs.) while using a wrench to maintain camshaft grip. After installing a new gasket with 2 nuts you should torque them to 9.0 Nm (92 kgf-cm, 80 inch lbs.) then turn the crankshaft counterclockwise to remove the plunger knock pin before confirming the plunger extension. Reinstall the wire harness protector clamp and bolt it at 8.4 Nm (85 kgf-cm, 74 inch lbs.) torque before performing clearance checks followed by needed valve adjustment then place the assembly of cylinder head cover sub-assembly, ignition coil assembly, engine mounting insulator RH, and vane pump assembly with Special Service Tool: 09249-63010. Complete the installation of the fan along with the generator V-belt then reconnect the battery negative terminal at 5.4 Nm (55 kgf-cm, 48 inch lbs.) before checking for any engine oil leaks. Finish the installation by putting on the engine cover sub-assembly No.1 and front fender apron seal RH together with engine under covers LH and RH and front wheel RH torqued to 103 Nm (1,050 kgf-cm, 76 ft. lbs.).

Clamp it in a vise, install the gear bolt washer and sub-gear, followed by the wave washer and snap ring, then align the holes of the main gear and sub-gear, and tighten the service bolt (torque: 5.4 Nm).

Remove the front wheel RH, front fender apron seal RH, engine cover sub-assembly No.1, spark plug, ventilation hoses, and engine wire.

Install the timing chain on the camshaft timing gear, aligning the painted mark with the timing marks of the camshaft timing sprocket, then install the bearing caps and bolts, tightening them in the specified sequence to the appropriate torque values.

Loosen and remove the bearing cap bolts in the specified sequence to take off the 5 bearing caps, then raise the No. 2 camshaft (exhaust) and remove it along with the sprocket bolt and camshaft timing sprocket.

Fix the camshaft (intake) in a vise, cover all paths with vinyl tape except the advanced side path, and apply about 150 kPa (1.5 kgf/cm2, 21 psi) of air pressure to the port on the advanced angle side.

Loosen the bearing cap bolts in the specified sequence, remove the camshaft, and tie the timing chain with a string, ensuring nothing drops inside the timing chain cover.

Disconnect the engine wire harness clamp and remove the bolts, 2 nuts, cylinder head cover, and gasket.

Turn the crankshaft counterclockwise to check the plunger knock pin and clockwise to ensure the slipper is pushed by the plunger.

Raise the ratchet pawl, push in the plunger, and apply the hook to the pin, then install a new gasket and the chain tensioner with 2 nuts, tightening to 9.0 Nm (92 kgf-cm, 80 inch lbs.).