Removal [04/2013 - 08/2015]: Procedure

WARNING: This page is about a different car, the 2015 Lexus IS 250 and 2014 Lexus IS 250. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE BATTERY
Refer to REMOVAL [04/2013 - 09/2020]
REMOVE FUEL PUMP ASSEMBLY
Refer to REMOVAL [04/2013 - 08/2015]
REMOVE GENERATOR ASSEMBLY
Refer to REMOVAL [04/2013 - 08/2015]
REMOVE NO. 1 ENGINE COVER
Refer to PROCEDURE - Step 6
REMOVE INJECTOR DRIVER
Refer to PROCEDURE - Step 7
REMOVE IGNITION COIL ASSEMBLY
Refer to PROCEDURE - Step 2
REMOVE SPARK PLUG
Refer to PROCEDURE - Step 3
REMOVE AIR CLEANER CASE SUB-ASSEMBLY
See step 24
REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE
Refer to PROCEDURE - Step 11
REMOVE NO. 1 OIL PIPE
Refer to PROCEDURE - Step 21
REMOVE NO. 2 OIL PIPE
Refer to PROCEDURE - Step 22

REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

Detach the clamps and disconnect the connectors to disconnect the wire harness from the cylinder head cover sub-assembly LH.

Remove the 12 bolts, cylinder head cover seal washer, cylinder head cover sub-assembly LH and cylinder head cover gasket LH.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Be careful of baffle plate

NOTE:

The baffle plate is located on the back of the portion shown in the illustration. Do not damage the baffle plate when removing the cylinder head cover sub-assembly LH.

HINT:

Make sure the removed parts are returned to the same places they were removed from.

Remove the 3 gaskets from the No. 3, No. 4 and No. 7 camshaft bearing caps.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	No. 3 Camshaft Bearing Cap
*2	No. 4 Camshaft Bearing Cap
*3	No. 7 Camshaft Bearing Cap

REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

Detach the clamps and disconnect the connectors to disconnect the wire harness from the cylinder head cover sub-assembly.

Remove the 14 bolts, 2 cylinder head cover seal washers, cylinder head cover sub-assembly and cylinder head cover gasket.

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HINT:

Make sure the removed parts are returned to the same places they were removed from.

Remove the 3 gaskets from the No. 1, No. 2 and No. 7 camshaft bearing caps.

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*1	No. 1 Camshaft Bearing Cap
*2	No. 2 Camshaft Bearing Cap
*3	No. 7 Camshaft Bearing Cap

REMOVE SPARK PLUG TUBE GASKET
Refer to PROCEDURE - Step 34

REMOVE TIMING CHAIN COVER PLATE

Remove the 4 bolts, timing chain cover plate and gasket.

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SET NO. 1 CYLINDER TO TDC / COMPRESSION

Turn the crankshaft pulley and align the notch with the "0" timing mark of the timing chain cover sub-assembly.

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Notch

Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing caps as shown in the illustration.

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*1	Timing Mark
*2	Paint Mark
*a	for Bank 2
*b	for Bank 1

HINT:

If the marks are not aligned, turn the crankshaft again to align the marks.

Place paint marks on the chain sub-assembly in alignment with the timing marks on each camshaft timing gear assembly and camshaft bearing cap.
HINT:

Be sure to place the paint marks on 2 links of the chain sub-assembly and on the sprockets of the camshaft timing gears at the locations of the timing marks of the camshaft timing gears.

REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

Turn the crankshaft approximately 30° counterclockwise so that there is some slack in the chain sub-assembly.

HINT:

This prevents the valves and pistons from interfering with each other.

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*a	0°
*b	30°

Align the hole in the stopper plate of the No. 1 chain tensioner assembly with the hole in the No. 1 chain tensioner body as shown in the illustration, and then insert a hexagon wrench into the hole.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Hole in the Stopper Plate
*2	Hole in the No. 1 Chain Tensioner Assembly
*3	Hexagon Wrench

Turn the crankshaft clockwise and align the notch with the "0" timing mark of the timing chain or belt cover sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Notch

Remove the 2 bolts and No. 1 chain tensioner assembly.

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NOTE:

Do not drop the No. 1 chain tensioner assembly or bolts into the timing chain or belt cover sub-assembly.

SEPARATE CHAIN SUB-ASSEMBLY (for Bank 1)

Turn the crankshaft clockwise until it is in the position shown in the illustration so that there is some slack in the chain sub-assembly between the banks.

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30°

WARNING:

As the camshafts turn suddenly, do not touch the camshafts or camshaft timing gears.

NOTE:

When turning the crankshaft, engine oil may spray out of the oil holes.

Turn the crankshaft clockwise until it is in the position shown in the illustration so that the chain sub-assembly can be removed easily.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

5 to 10°

NOTE:

When turning the crankshaft, engine oil may spray out of the oil holes.

Remove the chain sub-assembly from the sprocket of the camshaft timing gear assembly and set it on the camshaft timing gear assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

WARNING:

As the camshaft may turn suddenly and pinch your fingers when the chain sub-assembly is removed, pinch the chain sub-assembly and lift it upward to remove it from the sprocket.

REMOVE CAMSHAFT BEARING CAP (for Bank 1)

Remove the bolts and camshaft bearing caps in the order shown in the illustration.

Immediately after removing bearing caps, install service bolts and washers in the order shown in the illustration.

Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)

Fig 1: Camshaft Bearing Cap Bolts Loosening Sequence (Bank 1)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Service Bolt and Washers (used to temporarily secure the camshaft housing sub-assembly RH)
*a	Part to be removed
*b	Install the service bolts and washers to temporarily secure the camshaft housing sub-assembly RH

NOTE:

Do not install the camshaft bearing caps when installing the service bolts and washers.
Be sure to follow the numerical order when performing this procedure.
Do not allow the service bolts and washers to contact the camshaft.
Do not drop the service bolts and washers into the cylinder head sub-assembly.

HINT:

Arrange the removed parts so that they can be reinstalled in their original locations.
Part number for the service bolts used to temporarily secure the camshaft housing sub-assembly RH: 91551-G0845 (9 bolts)
Part number for the service washers used to temporarily secure the camshaft housing sub-assembly RH: 90201-12028 (18 washers)

REMOVE NO. 2 CAMSHAFT

Remove the bolt of the No. 2 chain tensioner assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Remove the No. 2 chain tensioner assembly while lifting up the No. 2 camshaft.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

While lifting up the No. 2 camshaft, pass it through the No. 2 chain sub-assembly and pull it out towards the front of the vehicle to remove it.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE CAMSHAFT

Lift up the rear of the camshaft so that it is at an angle.

Remove the chain sub-assembly from the camshaft timing gear assembly and pull out the camshaft and No. 2 chain sub-assembly towards the rear of the vehicle to remove them.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Do not drop the chain sub-assembly into the gap between the engine and timing chain cover sub-assembly.

Suspend the chain sub-assembly with a string or equivalent.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SEPARATE CHAIN SUB-ASSEMBLY (for Bank 2)

Turn the crankshaft counterclockwise and align the notch with the "0" timing mark of the timing chain or belt cover sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Notch

Remove the chain sub-assembly from the sprocket of the camshaft timing gear assembly and set it on the camshaft timing gear assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

WARNING:

As the camshaft may turn suddenly and pinch your fingers when the chain sub-assembly is removed, pinch the chain sub-assembly and lift it upward to remove it from the sprocket.

REMOVE CAMSHAFT BEARING CAP (for Bank 2)

Remove the bolts and camshaft bearing caps in the order shown in the illustration.

Immediately after removing bearing caps, install service bolts and washers in the order shown in the illustration.

Fig 2: Camshaft Bearing Caps Bolts Loosening Sequence (For Bank 2)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Service Bolt and Washers (used to temporarily secure the camshaft housing sub-assembly LH)
*a	Part to be removed
*b	Install the service bolts and washers to temporarily secure the camshaft housing sub-assembly LH

Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)

NOTE:

Do not install the camshaft bearing caps when installing the service bolts and washers.
Be sure to follow the numerical order when performing this procedure.
Do not allow the service bolts and washers to contact the camshaft.
Do not drop the service bolts and washers into the cylinder head LH.

HINT:

Arrange the removed parts so that they can be reinstalled in their original locations.
Part number for the service bolts used to temporarily secure the camshaft housing sub-assembly LH: 91551-G0845 (8 bolts)
Part number for the service washers used to temporarily secure the camshaft housing sub-assembly LH: 90201-12028 (16 washers)

REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY

Remove the bolt of the No. 3 chain tensioner assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Remove the No. 3 chain tensioner assembly while lifting up the No. 4 camshaft sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

While lifting up the No. 4 camshaft sub-assembly, pass it through the No. 2 chain sub-assembly and pull it out towards the front of the vehicle to remove it.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY

Lift up the rear of the No. 3 camshaft sub-assembly so that it is at an angle.

Remove the chain sub-assembly from the camshaft timing gear assembly and pull out the No. 3 camshaft sub-assembly and No. 2 chain sub-assembly towards the rear of the vehicle to remove them.

NOTE:

Do not drop the chain sub-assembly into the gap between the engine and timing chain cover sub-assembly.

Suspend the chain sub-assembly with a string or equivalent.

INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

Check the lock of the camshaft timing gear assembly.
1. Clamp the camshaft in a vise between aluminum plates, and confirm that the camshaft timing gear assembly is locked.
  NOTE:
  Be careful not to damage the camshaft.

Release the lock pin.

*1	Advanced Side Path
*2	Retard Side Path
*a	Open
*b	Close
	Rubber
	Vinyl Tape

Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.
HINT:

Plus 2 of the 4 paths with rubber pieces as shown in the illustration.
Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path, as shown in the illustration.

Apply approximately 200 kPa (2.0 kgf/cm² , 28 psi) of air pressure to the 2 opened paths.

*1	Advanced Side Path
*2	Retard Side Path

WARNING:

Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying.

Check that the camshaft timing gear assembly rotates in the advance direction when reducing the air pressure applied to the retard side path.

*1	Advance Side Path
*2	Retard Side Path
*a	Hold Pressure
*b	Decompress

HINT:

The lock pin is released and the camshaft timing gear assembly turns in the advance direction.

When the camshaft timing gear assembly reaches the most advanced position, release the air pressure first from the retard side path and next from the advance side path.
NOTE:
Do not release the air pressure from the advance side path first.

The gear may abruptly shift in the retard direction and break the lock pin.

Check for smooth rotation.
1. Turn the camshaft timing gear assembly within its movable range (21°) 2 or 3 times, but do not turn it to the most retarded position.
  Make sure that the camshaft timing gear assembly turns smoothly.
  
  NOTE:
  Do not use air pressure to perform the smooth operation check.
Check the lock in the most retarded position.
1. Confirm that the camshaft timing gear assembly locks at the most retarded position.

REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

Remove the flange bolt and camshaft timing gear assembly.

*1	Flange Bolt
*2	Straight Pin
*a	Do not remove

NOTE:

Do not remove the other 3 bolts.
If planning to reuse the camshaft timing gear, be sure to release the straight pin lock before installing the camshaft timing gear assembly.

INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

Check the lock of the camshaft timing exhaust gear assembly.
1. Clamp the camshaft in a vise between aluminum plates, and confirm that the camshaft timing exhaust gear assembly is locked.

Release the lock pin.

*1	Advanced Side Path
*2	Retard Side Path
*a	Open
*b	Close
	Rubber
	Vinyl Tape

Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.
HINT:

plus 2 of the 4 paths with rubber pieces as shown in the illustration
Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path, as shown in the illustration.

Apply approximately 200 kPa (2.0 kgf/cm² , 28 psi) of air pressure to the 2 opened paths (the advance side path and the retard side path).

*1	Advanced Side Path
*2	Retard Side Path

WARNING:

Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying.

Make sure that the camshaft timing exhaust gear assembly rotates in the retard direction when reducing the air pressure applied to the advance side path.

*1	Advance Side Path
*2	Retard Side Path
*a	Hold Pressure
*b	Decompress

HINT:

The lock pin is released and the camshaft timing exhaust gear assembly turns in the retard direction.

When the camshaft timing exhaust gear assembly moves to the most retarded position, release the air pressure first from the advance side path, and then release the air pressure from the retard side path.
NOTE:
Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear assembly may abruptly shift in the advance direction and break the lock pin or other parts.

Check for smooth rotation.
1. Turn the camshaft timing exhaust gear assembly within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advanced position.
  Make sure that the camshaft timing exhaust gear assembly turns smoothly.
  
  NOTE:
  When the air pressure is released from the advance side path and then from the retard side path, the camshaft timing exhaust gear assembly automatically returns to the most advanced position due to the advance assist spring operation and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check.
Check the lock at the most advanced position.
1. Make sure that the camshaft timing exhaust gear assembly locks at the most advanced position.

REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

Remove the flange bolt and camshaft timing exhaust gear assembly.

*1	Flange Bolt
*2	Straight Pin
*a	Do Not Remove

NOTE:

Be sure not to remove the other 4 bolts.
If planning to reuse the camshaft timing exhaust gear assembly, be sure to release the straight pin lock before installing the camshaft timing exhaust gear assembly.