Question 1

How is the camshaft timing gear assembly and camshaft installed, including timing chain alignment, bearing cap tightening, chain tensioner installation, and final component assembly with torque specifications and leak inspection on Toyota Camry?

Accepted Answer

The installation process involves positioning the camshaft timing gear and camshaft incorrectly with the straight pin outside the key groove until the operator turns the gear and rolls it against the camshaft until the pin locks into position. Perform this step without rotating toward the retard angle area. The gear must have no clearance with the camshaft before installing a torque of 54 Nm (551 kgf-cm, 40 ft-lbf) to the flange bolt. Check the movement and locking capability of the camshaft timing gear when it moves to its most retarded position on the retard angle side. A thin engine oil coating on the camshaft journal area is required before loading the camshaft timing gear and timing chain with the paint mark precisely matching the timing mark. Verification of all front notches and numbers should be completed before inserting the bearing caps into the cylinder head. The bearing cap bolts undergo a sequential tightening process in which the No. 1 bearing cap receives 30 Nm (301 kgf-cm, 22 ft-lbf) torque while the No. 3 bearing cap uses 9.0 Nm (92 kgf-cm, 80 in-lbf) torque. The entire process requires application of engine oil to the threads and under the heads of these bolts before uniform bolt tightening. You should place the No. 2 camshaft on the cylinder head with engine oil applied to its journal while making sure the paint marks line up with the timing marks. Then fasten the camshaft timing sprocket set bolt loosely and verify the front markings order before installing the bearing caps. Apply engine oil to each bearing cap bolt threads and under their heads before tightening all 10 bolts to 30 Nm (301 kgf-cm, 22 ft-lbf) for the No. 2 bearing caps and 9.0 Nm (92 kgf-cm, 80 in-lbf) for the No. 3 bearing caps. The technician should apply a wrench to the camshaft to torque the camshaft timing sprocket set bolt to 54 Nm (551 kgf-cm, 40 ft-lbf) while verifying that the chain paint marks match the camshaft timing gear and camshaft timing sprocket timing marks and the crankshaft pulley groove points to the timing mark "0" of the timing chain cover. The service calls for installation of the No. 1 chain tensioner assembly together with valve clearance measurement followed by cylinder head cover sub-assembly installation then the ignition coil assembly before moving on to install the No. 1 engine cover sub-assembly and the front fender apron seal RH before proceeding with engine under cover LH installation and engine under cover RH installation and front wheel RH installation and an engine oil leak check.

Question 2

How to remove the camshaft on Toyota Camry?

Accepted Answer

The first step to remove the 2AZ-FE engine camshaft involves the removal of front wheel RH, engine under cover LH, engine under cover RH, front fender apron seal RH, No. 1 engine cover sub-assembly, ignition coil assembly, and cylinder head cover sub-assembly. Set the Number One cylinder at TDC/compression position then take out the Number One chain tensioner assembly. A wrench should be used to stabilize the No. 2 camshaft before loosening its camshaft timing set bolt and following the stated sequence to individually loosen then extract the 10 bearing cap bolts for subsequent bearing cap removal. Hold the No. 2 camshaft while you remove the camshaft timing sprocket set bolt before extracting the timing sprocket with the attached chain followed by separating the sprocket from the chain. The removal process for the main camshaft proceeds by uniformly loosening and removing its 10 bearing cap bolts in sequence while removing the 5 bearing caps after extracting the camshaft and camshaft timing gear that necessitates timing chain support. The timing chain requires string tying to stop its descent into the timing chain cover. A vise needs to clamp the camshaft but the timing gear must remain static while vinyl tape covers all ports except the advance port and applying 100 kPa (1.0 kgf/cm2, 14 psi) pressurizes the oil flow during hand-rotation of the camshaft timing gear to the advance side (clockwise), maintaining shop rag coverage over all paths to prevent oil leakage. Finally when replacing the camshaft timing gear remove its flange bolt while keeping all other bolts in place and untie the straight pin lock if using a reused gear.

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