Toyota 13501-31040
Camshaft

The service and repair of the camshaft begins with battery cable removal from the negative terminal followed by engine coolant drainage. Start the service process by removing the V-bank cover with all bolts and seal washers along with the air cleaner assembly and throttle body bracket and oil baffle plate and surge tank stays No. 1 and No. 2 and intake air surge tank and ignition coil assembly as well as cylinder head cover sub-assemblies. Reach TDC compression in the No. 1 cylinder by setting the crankshaft pulley "0" timing mark adjacent to the groove while also having the markings on camshaft timing gears match bearing cap positions. Note down the timing marks on the No. 1 chain link before removing both the No. 1 chain tensioner assembly from the top of the crankshaft while keeping the crankshaft from rotating without the tensioner. The craftsman must lift the No. 2 camshaft to prevent damage and must detach the timing gear set bolt to separate the timing gear. The technician should perform the same procedure on the No. 2 chain tensioner assembly and No. 4 camshaft sub-assembly and No. 3 camshaft sub-assembly at this time while maintaining level orientation of all removed camshafts. The camshafts require a runout examination with V-blocks combined with a dial indicator, while measuring the cam lobe height requires a micrometer and checking the journal diameter. The installation of the camshaft timing gear assembly requires fixing the intake camshaft in a vise with hole alignment followed by bolt torque of 100 N m. The assembly requires confirmation of lock status followed by masking tape applied to oil paths before exposing it to compressed air as a check for proper locking at the most retarded position when removing the set bolt.

The installation procedure requires placement of the key groove and straight pin followed by light gear pressure against the camshaft and simultaneous gear turning as well as pushing at the groove insertion point while avoiding retard angle movement of the camshaft timing gear. The gear fringe must have no clearance from the camshaft while you tighten the fringe bolt to 78 Nm with torque and verify the camshaft timing gear movement into the extreme retard position. Put fresh engine oil on the camshaft cam section and cylinder head journals before installing the chain on the timing gear with painted markings directed toward the timing position while adjusting both camshafts correctly. Before final installation who should install the No. 1 camshaft bearing cap while checking that each No. 2 camshaft bearing cap occupies its proper position. Then place a new O-ring on the No. 1 camshaft bearing cap. Install the provisionary camshaft oil delivery pipe before tightening its mounting bolts according to the sequence and torque specifications of 12 Nm and 16 Nm. First check that each timing mark is correctly positioned then install the timing chain onto the camshaft timing gear and align the No. 2 camshaft straight pin with the camshaft timing gear straight pin hole before reducing the No. 2 camshaft rotation by using the hexagonal lobe when necessary. Attach an adjustable wrench to the hexagonal lobe while tightening the bolt to 78 Nm (795 kgf-cm, 58 ft-lbf). Using Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent apply adhesive to 2 or 3 threads of the head straight screw plug on the timing gear case before installing it with a 10 mm socket hexagon wrench to 17 Nm (170 kgf-cm, 12 ft-lbf) torque. A new O-ring should be installed on the camshaft bearing cap followed by the timing chain guide which must receive two bolts tightened to 10 Nm (102 kgf-cm, 7 ft-lbf). Install Toyota Genuine Seal Packing Black or Three Bond 1207B or an equivalent product at designated sites while ensuring surface oil removal before putting the cylinder head cover in place within three minutes and avoiding oil application for at least two post-installation hours. The cylinder head cover requires provisional bolt-on installation with 19 bolts together with 2 nuts. Begin by tightening bolts A to 9.0 Nm (92 kgf-cm, 80 in-lbf) then apply identical torque on nuts and bolts B before repeating the torque sequence for bolts A. Connect the ventilation hose followed by ignition coil bolt-on at 9.0 Nm (92 kgf-cm, 80 in-lbf) and engine wire harness clamp application and finally connect the camshaft position sensor connector, VSV connector, throttle with motor body connector, and ignition coil connectors. For the last step install Installation requires the under cover of the No. 1 engine secured with four bolts up to 30 Nm (306 kgf-cm, 22 ft-lbf) torque then the cable needs a 3.9 Nm (40 kgf-cm, 35 in-lbf) torque connection to the negative battery terminal. Before finishing the work add engine coolant while confirming no coolant or oil leakage occurs.

The camshaft (2TR-FE) service and repair begins with removing the negative battery cable followed by eliminating 4 bolts from the engine under cover sub-assembly Number One. The service requires draining engine coolant then separating the following elements to access the cylinder head cover sub-assembly: radiator support to frame seal LH, fan shroud, air cleaner cap sub-assembly, intake air connector, ignition coil connectors along with throttle with motor body connector, VSV connector, camshaft position sensor connector, engine wire harness clamps, ignition coils and 19 bolts and 2 nuts. Following the removal of 2 guide-bolts with an O-ring the timing chain guide can be taken out. Next, moving onto the camshaft extraction process requires setting the No.1 cylinder at TDC/compression while aligning crankshaft pulley timing mark with "0" before marking the timing chain plates and using an adjustable wrench to hold the hexagonal lobe on the No.2 camshaft while loosening the bolt which is followed by using a 10 mm socket hexagon wrench to remove the head straight screw plug. A screwdriver should be used to lift the chain tensioner stopper plate before rotating the No.2 camshaft clockwise by a small amount to push the plunger into position using a 3.0 mm (0.118 inch) diameter bar. Proceed with the camshaft timing gear removal process by uniformly loosening the 21 bearing cap bolts and afterward extracting the camshaft oil delivery pipe and O-ring before removing the camshaft bearing caps. Secure the chain with an appropriate tie to block external objects from accessing the engine compartment. Clamp the camshaft into a vise before you cover its oil paths with vinyl tape and puncture the tape to check the camshaft timing gear motion under air pressure when removing the fringe bolt. Place the camshaft timing gear on its position before gently pressing it while tightening the fringe bolt to 78 Nm (795 kgf-cm, 58 ft. lbs.). Mount the camshaft by treating it with clean engine oil and guiding the timing chain toward the camshaft timing gear before placing each camshaft bearing cap correctly with its O-ring installed. Begin by checking the specified bolt installation order then examine the timing marks before placing in the timing chain. Still one would need to integrate the timing chain guide alongside its new O-ring followed by placing the cylinder head cover sub-assembly with seal packing before torquing every bolt and nut according to specifications. The procedure requires reinstalling the intake air connector followed by the air cleaner cap sub-assembly and fan shroud then radiator support to frame seal LH while reconnecting the negative battery terminal before engine coolant addition and leak check for proper installation of engine under cover sub-assembly No. 1.

Apply new engine oil.

Use a socket hexagon wrench 8 to remove the four bolts, intake air surge tank, and gasket.

Turn the crankshaft pulley to align the notch with the timing mark "0" of the timing chain cover, ensuring the timing marks of the camshaft timing gears align with the bearing caps.

Ensure not to rotate the crankshaft with the chain tensioner removed, turn the stopper plate of the tensioner clockwise, push in the plunger, and fix the stopper plate by inserting a bar of diameter 3.5 mm (0.138 inch) into the holes.

Mount the hexagonal portion in a vise, turn the sub gear clockwise to remove the service bolt with Special Service Tool: 09960-10010, 09962-01000, and then use snap ring pliers to remove the snap ring, followed by the wave washer, sub gear, and gear spring.

Push in the tensioner while inserting a 1.0 mm pin to fix it, temporarily install the camshaft timing gear and No. 2 chain tensioner, and tighten the No. 2 chain tensioner bolt to 19 Nm.

Set the No. 1 camshaft onto the RH cylinder head with the lobes facing downward, install the bearing caps, and tighten the bolts in sequence to specified torque values.

Insert a new oil seal into the camshaft timing tube, aligning the timing tube knock pin with the drive gear's groove and temporarily installing the drive gear with 4 bolts, which should be uniformly tightened to a torque of 7.5 Nm.

Install the air cleaner assembly, connect ventilation hose No.2, add engine coolant, check for leaks, and install the V-bank cover with two nuts to the specified torque.

Align the yellow mark link with the timing mark (2 dot marks) of the camshaft timing gear.

Keep it level to avoid damage, use a pin to fix the No. 2 chain tensioner, and carefully loosen the bearing cap bolts in the specified sequence.

Disconnect the cable from the negative battery terminal and drain the engine coolant.

Insert a screwdriver into the service hole of the chain tensioner to lift the stopper plate.

Remove the No. 1 chain and the No. 1 chain vibration damper.

Apply clean engine oil, align the timing chain with the camshaft timing gear, and ensure the valve rocker arm is correctly set.

Remove the chain tensioner slipper, No. 1 idle gear shaft, and No. 2 chain vibration damper.

Disconnect the cable from the negative battery terminal and remove the No. 1 engine under cover sub-assembly by taking out the 4 bolts.

Insert a screwdriver into the service hole of the chain tensioner to hold the stopper plate lifted, then slightly rotate the No. 2 camshaft clockwise to push the plunger of the chain tensioner.