Camshaft (RH Bank) (3MZ-FE): Replacement

WARNING: This page is about a different car, the 2004 Lexus ES 330. However, it is still accessible from the selected car via links, so may be relevant.

DISCONNECT BATTERY NEGATIVE TERMINAL
DRAIN ENGINE COOLANT (See REPLACEMENT )
REMOVE FRONT WHEEL RH
REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See REPLACEMENT )
REMOVE V-BANK COVER SUB-ASSY (See REPLACEMENT )
REMOVE AIR CLEANER CAP SUB-ASSY (See REPLACEMENT )
REMOVE EMISSION CONTROL VALVE SET (See REPLACEMENT )
REMOVE INTAKE AIR SURGE TANK (See REPLACEMENT )
REMOVE IGNITION COIL ASSY
REMOVE CYLINDER HEAD COVER SUB-ASSY (See ADJUSTMENT )
REMOVE FRONT FENDER APRON SEAL RH
REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1 (See REPLACEMENT )
REMOVE VANE PUMP V BELT (See REPLACEMENT )
REMOVE ENGINE MOVING CONTROL ROD (See REPLACEMENT )
REMOVE ENGINE MOUNTING STAY NO. 2 RH (See REPLACEMENT )
REMOVE GENERATOR BRACKET NO. 2 (See REPLACEMENT )
REMOVE CRANKSHAFT PULLEY (See REPLACEMENT )
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05031)
REMOVE TIMING BELT NO. 1 COVER
REMOVE TIMING BELT NO. 2 COVER (See REPLACEMENT )
REMOVE ENGINE MOUNTING BRACKET RH (See REPLACEMENT )
REMOVE TIMING BELT GUIDE NO. 2
REMOVE TIMING BELT (See REPLACEMENT )
REMOVE TIMING BELT IDLER SUB-ASSY NO. 2
REMOVE CAMSHAFT TIMING PULLEY
1. Using SST, remove the bolt and RH timing pulley.
  SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
  
  Fig 1: Removing Bolt And RH Timing Pulley Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the bolt and LH timing pulley.
  SST 09960-10010 (09962-01000, 09963-01000)
  
  HINT:
  
  Arrange the camshaft timing pulleys (RH and LH sides) so that they can be returned to the original locations when reassembling.
  
  Fig 2: Removing Bolt And LH Timing Pulley Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TIMING BELT NO. 3 COVER
1. Disconnect the 3 engine wire harness clamps from the timing belt No. 3 cover.
2. Remove the 6 bolts and timing belt cover.
  
  Fig 3: Locating Timing Belt No. 3 Cover Bolts and Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being installed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must be carried out.
1. Align the timing marks (2 dot marks) of the camshaft drive and driven gears by turning the camshaft with a wrench.
  
  Fig 4: Turning Camshaft With Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Secure the exhaust camshaft sub gear to the main gear with a service bolt.
  Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
  
  Recommended service bolt
  
  Fig 5: Service Bolt Specification Table
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  When removing the camshaft, make certain that the torsional spring force of the sub gear has been eliminated by installation of the service bolt.
  
  Fig 6: Identifying Sub Gear And Main Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and camshaft.
  
  Fig 7: Identifying Bearing Cap Loosening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Do not pry out the camshaft.
  - Be careful not to damage the contact surface of the cylinder head that receives the shaft thrust.
REMOVE NO. 2 CAMSHAFT
1. Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and No. 2 camshaft.
  
  Fig 8: Loosening Bearing Cap Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Do not pry out the camshaft.
  - Be careful not to damage the contact surface of the cylinder head that receives the shaft thrust.
2. Remove the oil seal from the No. 2 camshaft.
REMOVE CAMSHAFT TIMING GEAR ASSY
NOTE: Do not remove or install the camshaft timing gear (VVT-i) unless you are replacing the VVT-i or camshaft.
1. Clamp the camshaft in a vise on the hexagonal lobe.
  
  Fig 9: Clamping Camshaft In Vise On Hexagonal Lobe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful not to damage the camshaft.
2. Using a 46 mm socket wrench, remove the lock nut by turning it clockwise.
  
  Fig 10: Removing Lock Nut Using Socket Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Remove it with the lock pin engaged and locked at the most retard angle position.
  - The lock nut has LH threads.
  - Never use any tools other than the socket wrench. Other tools will deform the cam angle rotor.
3. Remove the camshaft VVT-i.
  NOTE: Never remove the 3 bolts on the gear.
  
  If it is difficult to remove VVT-i, tap it lightly using a plastic-faced hammer, then remove it.
REMOVE CAMSHAFT SUB GEAR
1. Clamp the camshaft in a vise on the hexagonal lobe.
  
  Fig 11: Clamping Camshaft In Vise On Hexagonal Lobe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful not to damage the camshaft.
2. Using SST, turn the sub gear counterclockwise, then remove the service bolt.
  SST 09960-10010 (09962-01000, 09963-00500)
  
  Fig 12: Turning Sub Gear Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using snap ring pliers, remove the snap ring.
4. Remove the wave washer, camshaft sub gear and camshaft gear bolt washer.
  
  Fig 13: Removing Snap Ring Using Snap Ring Plier
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT SUB GEAR
1. Clamp the camshaft in a vise on the hexagonal lobe.
  
  Fig 14: Clamping Camshaft In Vise On Hexagonal Lobe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful not to damage the camshaft.
2. Install the camshaft gear bolt washer and camshaft sub gear.
  HINT:
  
  Attach the pins on the gears to the gear bolt washer ends.
3. Install the wave washer.
  
  Fig 15: Installing Camshaft Gear Bolt Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using snap ring pliers, install the snap ring.
  
  Fig 16: Installing Snap Ring Using Snap Ring Pliers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST, align the holes of the camshaft main gear and sub gear by turning the camshaft sub gear counterclockwise, then temporarily install a service bolt.
  SST 09960-10010 (09962-01000, 09963-00500)
  
  Fig 17: Aligning Holes Of Camshaft Main Gear Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Align the gear teeth of the main gear and sub gear, then tighten the service bolt.
  Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
  
  NOTE: Be careful not to damage the camshaft journals.
  
  HINT:
  
  When installing the camshaft, make certain that the torsional spring force of the sub gear has been eliminated by installation of the service bolt.
INSTALL CAMSHAFT TIMING GEAR ASSY
1. Align the alignment pin with the alignment pin groove, then install the VVT-i on the camshaft.
  
  Fig 18: Installing Camshaft Timing Gear Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Install it with the lock pin engaged and locked at the most retard angle position.
2. Apply engine oil to the nut, mounting surface of the VVT-i and screw threads.
  NOTE:
  - Be sure to apply the oil, otherwise the specified torque cannot be obtained.
  - New nut must be used when replacing the VVT-i unit.
3. Using a 46 mm socket wrench, install and tighten a lock nut by turning it counterclockwise.
  Torque: 150 N.m (1,530 kgf.cm, 111 ft.lbf)
  
  Fig 19: Installing And Tightening Lock Nut Using Socket Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - The lock nut has LH threads.
  - Never use any tools other than the socket wrench. Other tools will deform the cam angle rotor.
INSTALL NO. 2 CAMSHAFT
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being installed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must be carried out.
1. Apply new engine oil to the thrust portion and journal of the camshaft.
2. Place the No. 2 camshaft at a 90° angle of the timing mark (2 dot marks) on the cylinder head.
3. Apply multi-purpose grease to a new oil seal lip.
  
  Fig 20: Placing Camshaft At 90deg Angle Of Timing Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the oil seal to the camshaft.
  NOTE:
  - Do not turn over the oil seal lip.
  - Insert the oil seal until it stops.
5. Remove any old packing material from the contact surface.
  
  Fig 21: Installing Oil Seal To Camshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Apply seal packing to the bearing cap No. 1 as shown in the illustration.
  Seal packing: Part No. 08826-00080 or equivalent
  
  Fig 22: Identifying Seal Packing Of Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Install the bearing cap No. 1 within 5 minutes after applying seal packing.
  - Do not expose the seal packing to engine oil within 2 hours after installing.
7. Install the 5 bearing caps in their proper locations.
8. Apply a light coat of engine oil to the threads of the bearing cap bolts.
  
  Fig 23: Installing Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
  Torque: 16 N.m (163 kgf.cm, 12 ft.lbf)
  
  Fig 24: Identifying Bearing Cap Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being installed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must be carried out.
1. Apply new engine oil to the thrust portion and journal of the camshaft.
2. Align the timing marks (2 dot marks) of the camshaft drive and driven gears.
3. Place the camshaft on the cylinder head.
  
  Fig 25: Aligning Timing Marks Of Camshaft Drive
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 5 bearing caps in their proper locations.
5. Apply a light coat of engine oil to the threads of the bearing cap bolts.
  
  Fig 26: Installing Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
  Torque: 16 N.m (163 kgf.cm, 12 ft.lbf)
  
  Fig 27: Identifying Bearing Cap Tightening sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Remove the service bolt.
INSTALL TIMING BELT NO. 3 COVER
1. Visually check for cracks and breaks on the gasket of the timing belt cover.
  HINT:
  
  If there is a trace of water intrusion when checking visually, repair the gasket with seal packing when the crack length is within 2 to 3 cm (0.79 to 1.18 in.). Replace the gasket when the crack length is 3 to 4 cm (1.18 to 1.57 in.) or longer.
2. If the timing belt cover gasket is needed to repair, follow the procedure below.
  1. Repair the cracks and breaks by applying seal packing to the damaged area.
    Seal packing: Part No. 08826-00080 or equivalent
    
    Fig 28: Identifying Seal Packing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE: When applying the seal packing, apply it as wide and high as the gasket.
3. If the timing belt cover gasket is needed to replace, follow the procedure below.
  1. Using a screwdriver and gasket scraper, remove the remaining gasket.
    NOTE: Be careful not to damage the timing belt cover.
  2. Remove the backing paper from a new gasket, then affix the gasket along the groove of the timing belt cover as shown in the illustration.
    
    Fig 29: Gasket Specification Table
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    Affix the gasket in the center of the groove.
    
    At the corners, try to keep the gasket thickness uniform.
    HINT:
    
    Fig 30: Identifying Seal Packing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. If there is a gap between the ends of the gasket, apply seal packing to close the gap.
    Seal packing: Part No. 08826-00080 or equivalent
    
    NOTE: When applying the seal packing, apply it as wide and high as the gasket.
4. Install the timing belt cover with the 6 bolts.
  Torque: 8.5 N.m (87 kgf.cm, 75 in.lbf)
INSTALL CAMSHAFT TIMING PULLEY
1. Pay attention to the orientation of the belt guide. Install the camshaft timing pulley with the belt guide properly oriented, then tighten the bolt temporarily.
  HINT:
  - Align the belt guide of the RH timing pulley so it faces the front of the engine as illustrated.
  - Align the belt guide of the LH timing pulley so it faces the rear of the engine as illustrated.
    
    Fig 31: Installing Camshaft Timing Pulley
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, tighten the RH pulley bolt.
  SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
  
  Torque: 125 N.m (1,275 kgf.cm, 92 ft.lbf)
  
  Fig 32: Tightening RH Pulley Bolt Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: The torque indicated above is used without SST on the extension tool. If you are using the extension tool, find the reading of the torque wrench by the formula (see ).
  
  Extended length:
  
  SST (09249-63010) 150mm (5.91 in.)
  
  Fig 33: Tightening LH Pulley Bolt Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, tighten the LH pulley bolt.
  SST 09960-10010 (09962-01000, 09963-01000)
  
  Torque: 125 N.m (1275 kgf.cm, 92 ft.lbf)
INSTALL TIMING BELT IDLER SUB-ASSY NO. 2
Torque: 43 N.m (438 kgf.cm, 32 ft.lbf)
INSPECT TIMING BELT (See REPLACEMENT )
INSTALL TIMING BELT (See REPLACEMENT )
SST 09960-10010 (09962-01000, 09963-01000)
INSTALL TIMING BELT TENSIONER ASSY (See REPLACEMENT )
INSTALL TIMING BELT GUIDE NO. 2 (See REPLACEMENT )
INSTALL ENGINE MOUNTING BRACKET RH (See REPLACEMENT )
INSTALL TIMING BELT NO. 2 COVER (See REPLACEMENT )
INSTALL TIMING BELT NO. 1 COVER (See REPLACEMENT )
INSTALL CRANKSHAFT PULLEY (See REPLACEMENT )
SST 09213-54015 (91651-60855), 09330-00021
INSTALL GENERATOR BRACKET NO. 2 (See REPLACEMENT )
INSTALL ENGINE MOUNTING STAY NO. 2 RH (See REPLACEMENT )
INSTALL ENGINE MOVING CONTROL ROD (See REPLACEMENT )
INSPECT VALVE CLEARANCE (See ADJUSTMENT )
ADJUST VALVE CLEARANCE (See ADJUSTMENT )
SST 09248-55040 (09248-05410, 09248-05420)
INSTALL VANE PUMP V BELT (See REPLACEMENT )
INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1 (See REPLACEMENT )
INSPECT DRIVE BELT DEFLECTION AND TENSION (See INSPECTION )
INSTALL CYLINDER HEAD COVER SUB-ASSY (See ADJUSTMENT )
INSTALL IGNITION COIL ASSY (See ADJUSTMENT )
INSTALL INTAKE AIR SURGE TANK (See REPLACEMENT )
INSTALL EMISSION CONTROL VALVE SET (See REPLACEMENT )
INSTALL AIR CLEANER CAP SUB-ASSY (See REPLACEMENT )
CHECK CONNECTION OF VACUUM HOSE (See REPLACEMENT )
INSTALL V-BANK COVER SUB-ASSY (See REPLACEMENT )
INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See REPLACEMENT )
INSTALL FRONT WHEEL RH (See REPLACEMENT )
ADD ENGINE COOLANT (See REPLACEMENT )
CHECK FOR ENGINE COOLANT LEAKS (See INSPECTION )
SYSTEM INITIALIZATION (See PRECAUTION )