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Engine Mechanical (Hybrid): Camshaft: Removal

  1. REMOVE ENGINE ROOM SIDE LH COVER NO.2 (See  REMOVAL   ) 
  2. DRAIN COOLANT  (See COOLANT )
  3. DRAIN ENGINE OIL  (See OIL AND OIL FILTER )
  4. REMOVE FRONT WHEEL RH 
  5. REMOVE ENGINE UNDER COVER NO.1 (See  REMOVAL   ) 
  6. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (See  REMOVAL   ) 
  7. REMOVE FRONT FENDER APRON SEAL RH (See  REMOVAL   ) 
  8. REMOVE FRONT SUSPENSION BRACE SUB-ASSEMBLY UPPER CENTER (See  REMOVAL   ) 
  9. REMOVE BATTERY (See  REMOVAL   ) 
  10. REMOVE BATTERY CARRIER SUB-ASSEMBLY (See  REMOVAL   ) 
  11. REMOVE AIR CLEANER CAP W/INLET (See  REMOVAL   ) 
  12. REMOVE AIR CLEANER CASE W/ RESONATOR  (See REMOVAL )
  13. REMOVE EMISSION CONTROL VALVE SET  (See REMOVAL )
  14. REMOVE INTAKE AIR SURGE TANK  (See REMOVAL )
  15. DISCONNECT RADIATOR HOSE INLET 
  16. SEPARATE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY (See  REMOVAL   ) 
  17. REMOVE RESERVOIR BRACKET (See  REMOVAL   ) 
  18. REMOVE AIR CLEANER BRACKET (See  REMOVAL   ) 
  19. REMOVE ENGINE MOVING CONTROL ROD (See  REMOVAL   ) 
  20. REMOVE ENGINE MOUNTING STAY NO.2 RH (See  REMOVAL   ) 
  21. REMOVE IGNITION COIL ASSEMBLY 
  22. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (See  ADJUSTMENT   ) 
  23. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH (See  ADJUSTMENT   ) 
  24. REMOVE CRANKSHAFT PULLEY (See  REMOVAL   ) 
  25. REMOVE TIMING BELT NO.1 COVER (See  REMOVAL   ) 
  26. REMOVE TIMING BELT NO.2 COVER (See  REMOVAL   ) 
  27. REMOVE ENGINE MOUNTING BRACKET RH (See  REMOVAL   ) 
  28. REMOVE TIMING BELT GUIDE NO.2 
  29. REMOVE TIMING BELT (See  REMOVAL   ) 
  30. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO.2 
    1. Remove the bolt and timing belt idler sub-assembly No.2
  31. REMOVE CAMSHAFT TIMING PULLEY 
    1. Using SST, remove the bolt and the RH timing pulley.

      SST 09960-10010 (09962-01000, 09963-01000), 09249-63010 

      Fig 1: Removing Bolt And RH Timing Pulley
      G05200353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the bolt and the 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
      G05200354Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE TIMING BELT NO.3 COVER 
    1. Disconnect the 2 engine wire harness clamps from the timing belt No.3 cover.
    2. Remove the 6 bolts and the timing belt cover.
      Fig 3: Locating Timing Belt Cover With Bolts
      G05200355Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE CAMSHAFT 
    NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.
    1. Align the timing marks (2-dot mark) of the camshaft drive and the driven gears by turning the camshaft with a wrench.
      Fig 4: Identifying Timing Marks Of Camshaft Drive And Driven Gears
      G05200356Courtesy 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: 

      SERVICE BOLT SPECIFICATION

      Thread diameter 6 mm
      Thread pitch 1.0 mm
      Bolt length 16 to 20 mm
      Fig 5: Securing Exhaust Camshaft Sub Gear To Main Gear With Service Bolt
      G05129430Courtesy 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 installing the service bolt.

    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 the camshaft.
      Fig 6: Identifying Bearing Cap Bolts Loosening Sequence
      G05129431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not pry out the camshaft.
      • Do not damage the portion of the cylinder head which receives the shaft thrust.
  34. 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 the No.2 camshaft.
      Fig 7: Identifying Bearing Cap Bolts Loosening Sequence
      G05200359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not pry out the camshaft.
      • Do not damage the portion of the cylinder head which receives the shaft thrust.
    2. Remove the oil seal from the No.2 camshaft.
  35. REMOVE NO.3 CAMSHAFT SUB-ASSEMBLY 
    NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.
    1. Align the timing marks (1-dot mark) of the camshaft drive and the driven gears by turning the camshaft with a wrench.
      Fig 8: Aligning Camshaft Drive And Driven Gear's Timing Marks
      G05129433Courtesy 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: 

      SERVICE BOLT SPECIFICATION

      Thread diameter 6 mm
      Thread pitch 1.0 mm
      Bolt length 16 to 20 mm

      HINT:

      When removing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by installing the service bolt.

      Fig 9: Securing Exhaust Camshaft Sub Gear To Main Gear With Service Bolt
      G05129434Courtesy 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 the No.3 camshaft.
      NOTE:
      • Do not pry out the camshaft.
      • Do not damage the portion of the cylinder head which receives the shaft thrust.
        Fig 10: Identifying Loosening Sequence Of Bearing Cap Bolts
        G05200362Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE NO.4 CAMSHAFT SUB-ASSEMBLY 
    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 the No.4 camshaft.
      NOTE:
      • Do not pry out the camshaft.
      • Do not damage the portion of the cylinder head which receives the shaft thrust.
    2. Remove the oil seal from the No.4 camshaft.
      Fig 11: Identifying Loosening Sequence Of Bearing Cap Bolts
      G05200363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY 
    NOTE: Do not remove or install the camshaft timing gear (VVT-i) unless the VVT-i or the camshaft needs to be replaced.
    1. Clamp the camshaft in a vise on the hexagonal lobe.
      NOTE: Do not damage the camshaft.
      Fig 12: Clamping Camshaft In A Vise On Hexagonal Lobe
      G05200364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a 46 mm socket wrench, remove the lock nut by turning it clockwise.
      Fig 13: Removing Lock Nut With Turning
      G05200365Courtesy 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 left-hand threads.
      • Never use any tool 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 the VVT-i, tap it lightly using a plastic-faced hammer and then remove it.

  38. REMOVE CAMSHAFT SUB GEAR 
    1. Clamp the camshaft in a vise on the hexagonal lobe.
      NOTE: Do not damage the camshaft.
      Fig 14: Removing Camshaft Sub Gear
      G05200366Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, turn the sub-gear counterclockwise, and remove the service bolt.

      SST 09960-10010 (09962-01000, 09963-00500) 

      Fig 15: Removing Service Bolt
      G05200367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using snap ring pliers, remove the snap ring.
      Fig 16: Removing Snap Ring
      G05200368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the wave washer, camshaft sub-gear and camshaft gear bolt washer.
      Fig 17: Identifying Wave Washer, Camshaft Sub-Gear, Camshaft Gear Bolt Washer
      G05200369Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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