Section 207 (Engine Mechanical): Camshaft: Removal

WARNING: This page is about a different car, the 2008 Toyota Yaris. However, it is still accessible from the selected car via links, so may be relevant.

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
REMOVE ENGINE UNDER COVER RH
REMOVE CYLINDER HEAD COVER NO. 2 REMOVAL
REMOVE IGNITION COIL NO. 1 REMOVAL
DISCONNECT VENTILATION HOSE (See REMOVAL )
DISCONNECT VENTILATION HOSE NO. 2 (See REMOVAL )
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (See REMOVAL )
REMOVE FAN AND GENERATOR V BELT (See REMOVAL )
REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH (See REMOVAL )
REMOVE NO. 2 CAMSHAFT
NOTE: When rotating the camshaft with the timing chain removed, rotate the crankshaft damper counterclockwise 40 ° from the TDC and align its timing notch with the matchmark of the timing chain cover to prevent the pistons from coming into contact with the valves.

Fig 1: Identifying Matchmark Of Timing Chain Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Set the No. 1 cylinder to TDC / compression.
  1. Turn the crankshaft damper, and align its timing notch with the timing mark "0" of the oil pump.
    
    Fig 2: Identifying Timing Notch
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Check that the timing marks on both the camshaft timing sprocket and the camshaft timing gear are facing upward, as shown in the illustration.
    HINT:
    
    If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.
    
    Fig 3: Identifying Timing Marks
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Place paint marks on the chain in the places where the timing marks of the camshaft timing sprocket and the camshaft timing gear are located.
  
  Fig 4: Identifying Paint Marks And Timing Marks Of Camshaft Timing Sprocket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using an 8 mm hexagon wrench, remove the screw plug.
  
  Fig 5: Locating Screw Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Insert a screwdriver into the service hole in the chain tensioner to pull the stopper plate of the chain tensioner upward.
  
  Fig 6: Identifying Stopper Plate Of Chain Tensioner
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a wrench, rotate camshaft No. 2 clockwise to push in the plunger of the chain tensioner.
  
  Fig 7: Pushing In Plunger Of Chain Tensioner
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Remove the screwdriver from the service hole, then align the hole in the stopper plate with the service hole and insert a 3 mm (0.12 in.) diameter bar into the holes to hold the stopper plate.
  HINT:
  - Fix the stopper plate using the bar while rotating the camshaft right and left slightly.
  - Hold the bar with tape so that it does not come off.
    
    Fig 8: Rotating Camshaft Right And Left
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using a wrench, hold the hexagonal lobe of camshaft No. 2 and remove the flange bolt.
  
  Fig 9: Locating Fringe Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Using several steps, loosen and remove the 11 bearing cap bolts uniformly in the sequence shown in the illustration, then remove camshaft bearing caps No. 1 and No. 2.
  NOTE: Loosen the bolts uniformly while keeping the camshaft level.
  
  Fig 10: Identifying Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Remove the flange bolt and remove the camshaft timing sprocket.
  
  Fig 11: Identifying Fringe Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Remove camshaft No. 2.
  
  Fig 12: Identifying Camshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT
1. Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence shown in the illustration, then remove camshaft bearing cap No. 2.
  NOTE: Loosen each bolt uniformly while keeping the camshaft level.
  
  Fig 13: Identifying Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Hold the chain by hand, and remove the camshaft and the camshaft timing gear assembly.
  
  Fig 14: Identifying Camshaft And Camshaft Timing Gear Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Tie the chain with a piece of string as shown in the illustration.
REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
1. Clamp the camshaft in a vise and confirm that it is locked.
  NOTE: Do not damage the camshaft.
  
  Fig 15: Identifying Tie Chain With Piece Of String
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Cover the 4 oil paths of the cam journal with tape as shown in the illustration.
  HINT:
  
  One of the 2 grooves located on the cam journal is for retarding cam timing (upper) and the other is for advancing cam timing (lower). Each groove has 2 oil paths. Plug one of the oil paths for each groove with a piece of rubber before wrapping the cam journal with the tape.
3. Puncture the tape covering the advance oil path and the retard oil path on the opposite side from the advance oil path.
  
  Fig 16: Identifying Cam Journal With Tape
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Apply air at about 150 kPa (1.5 kgf*cm² ) pressure into the 2 broken paths (the advance side path and the retard side path).
  NOTE: Cover the paths with a shop rag or piece of cloth to prevent oil splashes.
  
  Fig 17: Applying Air Pressure Advance Side Path And Retard Side Path
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Confirm that the camshaft timing gear assembly revolves in the timing advance direction when the air pressure on the timing retard path is reduced.
  HINT:
  
  The lock pin is released, and the camshaft timing gear revolves in the advance direction.
6. When the camshaft timing gear reaches the most advanced position, release the air pressure on the timing retard side path, and then release the air pressure on the timing advance side path.
  NOTE: The camshaft timing gear assembly occasionally shifts to the retard side abruptly, if the air pressure on the advance side path is released first. This often results in breakage of the lock pin.
  
  Fig 18: Applying Air Pressure On Advance Side, Side Path Retard Side, Side Path
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Remove the flange bolt and remove the camshaft timing gear assembly.
  NOTE:
  - Do not remove the other 4 bolts.
  - When reusing the camshaft timing gear, unlock the lock pin inside the camshaft timing gear first.
    
    Fig 19: Identifying Camshaft Timing Gear Assembly And Flange Bolt
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002