Camry 2008-2009

Camshaft & Timing Gears 2

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Removal & Installation



2.4L Engine
Hybrid

Specific to:

Toyota Camry 2007-2008


CAUTION
Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions, such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. Make sure to turn the power switch off before removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.


CAUTION
All models are equipped with a Supplemental Restraint System (SRS), which uses an air bag. Whenever working near any of the SRS components, such as the impact sensors, the air bag module, steering column and instrument panel, disable the SRS.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Loosen the lug nuts on the front right hand wheel.
  6.  
  7. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle securely on jackstands.
  8.  
  9. Remove the front right hand wheel.
  10.  
  11. Remove the left and right hand under cover.
  12.  
  13. Remove the No.1 engine cover sub-assembly and 2 nuts.
  14.  
  15. Remove the ignition coil assembly.
  16.  
  17. Remove the cylinder head cover sub-assembly

    Click image to see an enlarged view

    Fig. Setting No. 1 cylinder to TDC/Compression

  18.  
  19. Set No.1 Cylinder to TDC/Compression by performing the following:
    NOTE
    Do not turn the crankshaft without the chain tensioner.



    Turn the crankshaft pulley until its groove and the timing mark "0" of the timing chain cover are aligned
     
    Check that each timing mark of the camshaft timing gear and sprocket is aligned with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration. If not, turn the crankshaft by 1 revolution (360°) to align the timing marks
     

  20.  
  21. Remove the No.1 Chain tensioner assembly. Remove the 2 nuts, tensioner and gasket.
  22.  
  23. Remove the No. 2 camshaft by performing the following:
    1. While holding the camshaft with a wrench, loosen the camshaft timing set bolt.

      Click image to see an enlarged view

      Fig. No. 2 camshaft bearing cap bolt removal sequence

    2.  
    3. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
    4.  
    5. While holding the No. 2 camshaft by hand, remove the camshaft timing sprocket set bolt.
    6.  
    7. Remove the camshaft timing sprocket from the No. 2 camshaft with the timing chain wrapped on the sprocket.
    8.  
    9. Remove the camshaft timing sprocket from the timing chain.
    10.  

  24.  
  25. Remove the No. 1 camshaft by performing the following:
    1. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

      Click image to see an enlarged view

      Fig. No.1 camshaft bearing cap bolt removal sequence

    2.  
    3. Remove the 5 bearing caps.
    4.  
    5. Remove the camshaft and camshaft timing gear while holding the timing chain by hand.
      NOTE
      Be careful not to drop anything inside the timing chain cover.

    6.  
    7. Tie the timing chain with a string.
    8.  

  26.  
  27. Remove the camshaft timing gear assembly by performing the following:
    1. Clamp the camshaft in a vise, and make sure that the camshaft timing gear does not rotate.
    2.  
    3. Cover all the oil ports except the advance side port shown in the illustration with vinyl tape
      NOTE
      Cover the paths with a shop rag or piece of cloth to avoid oil splashes.


      NOTE
      Depending on the air pressure, the camshaft timing gear will turn to the advance angle side without applying force by hand. Also, if the pressure is difficult to apply because of air leakage from the port, the lock may be difficult to release.

    4.  
    5. Apply air pressure of 14 psi to the oil path, then turn the camshaft timing gear in the advance direction (counterclockwise) by hand.
    6.  
    7. Remove the flange bolt of the camshaft timing gear. Be sure not to remove the other four bolts. If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.

      Click image to see an enlarged view

      Fig. Removing the flange bolt from the camshaft timing gear

    8.  

  28.  

To install:

Click image to see an enlarged view

Fig. No. 1 camshaft straight pin and key groove misaligned

  1. Put the camshaft timing gear and camshaft together with the straight pin and key groove misaligned.
    NOTE
    Be sure not to turn the camshaft timing gear to the retard angle side (the right angle).

  2.  
  3. Turn the camshaft timing gear as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.
  4.  
  5. Check that there is no clearance between the gear and camshaft.
  6.  
  7. Tighten the flange bolt with the camshaft timing gear fixed in place and tighten to 40 ft. lbs. (54 Nm).
  8.  
  9. Check that the camshaft timing gear can move to the retard angle side (the right direction) and is locked in the most retarded position.
  10.  
  11. To install the No.1 camshaft, perform the following:
    1. Apply a light coat of engine oil to the journal portion of the camshaft.
    2.  
    3. Install the timing chain onto the camshaft timing gear with the paint mark aligned with the timing mark in the camshaft timing gear.

      Click image to see an enlarged view

      Fig. Aligning No. 1 camshaft paint mark with the timing mark



      Click image to see an enlarged view

      Fig. Checking the No. 1 camshaft bearing cap front marks, numbers and order

    4.  
    5. Examine the front marks and numbers, and check that the order is as shown in the illustration below. Then install the bearing caps into the cylinder head.
    6.  
    7. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

      Click image to see an enlarged view

      Fig. No. 1 camshaft bearing cap tightening sequence

    8.  
    9. Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Tighten the following to specification:

      No. 1 Bearing cap: 22 ft. lbs. (30 Nm)
       
      No. 3 Bearing cap: 80 inch lbs. (9 Nm)
       

    10.  

  12.  
  13. To install camshaft No. 2, perform the following:
    1. Apply a light coat of engine oil to the journal portion of the No. 2 camshaft.
    2.  
    3. Put the No. 2 camshaft on the cylinder head with the paint mark of the chain aligned with the timing mark on the camshaft timing sprocket.

      Click image to see an enlarged view

      Fig. Aligning No. 2 camshaft paint mark with the timing mark

    4.  
    5. While holding the No. 2 camshaft by hand, temporarily tighten the camshaft timing sprocket set bolt.
    6.  
    7. Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head.

      Click image to see an enlarged view

      Fig. Checking the No. 2 camshaft bearing cap front marks, numbers and order

    8.  
    9. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

      Click image to see an enlarged view

      Fig. No. 2 camshaft bearing cap tightening sequence

    10.  
    11. Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Tighten the following to specification:

      No. 1 Bearing cap: 22 ft. lbs. (30 Nm)
       
      No. 3 Bearing cap: 80 inch lbs. (9 Nm)
       

    12.  
    13. While holding the camshaft with a wrench, tighten the camshaft timing sprocket set bolt and tighten to 40 ft. lbs. (54 Nm).

      Click image to see an enlarged view

      Fig. Aligning paint marks on the chain with the timing marks on the camshaft timing gear and camshaft timing sprocket

    14.  
    15. Check that the paint marks on the chain are aligned with the timing marks on the camshaft timing gear and camshaft timing sprocket. Also, check that the crankshaft pulley groove is aligned with the timing mark -0- of the timing chain cover.
    16.  

  14.  
  15. To complete installation, reverse remaining removal procedure.
  16.  
  17. Check engine for oil leaks.
  18.  
  19. Connect the negative battery cable.
  20.  

Non-hybrid

Specific to:

Toyota Camry 2007-2008

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Loosen the lug nuts on the front right hand wheel.
  6.  
  7. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle securely on jackstands.
  8.  
  9. Remove the front right hand wheel.
  10.  
  11. Remove the left and right hand under cover.
  12.  
  13. Remove the No.1 engine cover sub-assembly and 2 nuts.
  14.  
  15. Remove the ignition coil assembly.
  16.  
  17. Remove the cylinder head cover sub-assembly

    Click image to see an enlarged view

    Fig. Setting No. 1 cylinder to TDC/Compression

  18.  
  19. Set No.1 Cylinder to TDC/Compression by performing the following:
    NOTE
    Do not turn the crankshaft without the chain tensioner.



    Turn the crankshaft pulley until its groove and the timing mark "0" of the timing chain cover are aligned
     
    Check that each timing mark of the camshaft timing gear and sprocket is aligned with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration. If not, turn the crankshaft by 1 revolution (360°) to align the timing marks
     

  20.  
  21. Remove No.1 Chain tensioner assembly. Remove the 2 nuts, tensioner and gasket.
  22.  
  23. Remove the No. 2 camshaft by performing the following:
    1. While holding the camshaft with a wrench, loosen the camshaft timing set bolt.

      Click image to see an enlarged view

      Fig. No. 2 camshaft bearing cap bolt removal sequence

    2.  
    3. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
    4.  
    5. While holding the No. 2 camshaft by hand, remove the camshaft timing sprocket set bolt.
    6.  
    7. Remove the camshaft timing sprocket from the No. 2 camshaft with the timing chain wrapped on the sprocket.
    8.  
    9. Remove the camshaft timing sprocket from the timing chain.
    10.  

  24.  
  25. Remove the No. 1 camshaft by performing the following:
    1. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

      Click image to see an enlarged view

      Fig. No.1 camshaft bearing cap bolt removal sequence

    2.  
    3. Remove the 5 bearing caps.
    4.  
    5. Remove the camshaft and camshaft timing gear while holding the timing chain by hand.
      NOTE
      Be careful not to drop anything inside the timing chain cover.

    6.  
    7. Tie the timing chain with a string.
    8.  

  26.  
  27. Remove the camshaft timing gear assembly by performing the following:
    1. Clamp the camshaft in a vise, and make sure that the camshaft timing gear does not rotate.
    2.  
    3. Cover all the oil ports except the advance side port shown in the illustration with vinyl tape
      NOTE
      Cover the paths with a shop rag or piece of cloth to avoid oil splashes.


      NOTE
      Depending on the air pressure, the camshaft timing gear will turn to the advance angle side without applying force by hand. Also, if the pressure is difficult to apply because of air leakage from the port, the lock may be difficult to release.

    4.  
    5. Apply air pressure of 14 psi to the oil path, then turn the camshaft timing gear in the advance direction (counterclockwise) by hand.
    6.  
    7. Remove the flange bolt of the camshaft timing gear. Be sure not to remove the other four bolts. If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.

      Click image to see an enlarged view

      Fig. Removing the flange bolt from the camshaft timing gear

    8.  

  28.  

To install:

Click image to see an enlarged view

Fig. No. 1 camshaft straight pin and key groove misaligned

  1. Put the camshaft timing gear and camshaft together with the straight pin and key groove misaligned.
    NOTE
    Be sure not to turn the camshaft timing gear to the retard angle side (the right angle).

  2.  
  3. Turn the camshaft timing gear as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.
  4.  
  5. Check that there is no clearance between the gear and camshaft.
  6.  
  7. Tighten the flange bolt with the camshaft timing gear fixed in place and tighten to 40 ft. lbs. (54 Nm).
  8.  
  9. Check that the camshaft timing gear can move to the retard angle side (the right direction) and is locked in the most retarded position.
  10.  
  11. To install the No.1 camshaft, perform the following:
    1. Apply a light coat of engine oil to the journal portion of the camshaft.
    2.  
    3. Install the timing chain onto the camshaft timing gear with the paint mark aligned with the timing mark in the camshaft timing gear.

      Click image to see an enlarged view

      Fig. Aligning No. 1 camshaft paint mark with the timing mark



      Click image to see an enlarged view

      Fig. Checking the No. 1 camshaft bearing cap front marks, numbers and order

    4.  
    5. Examine the front marks and numbers, and check that the order is as shown in the illustration below. Then install the bearing caps into the cylinder head.
    6.  
    7. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

      Click image to see an enlarged view

      Fig. No. 1 camshaft bearing cap tightening sequence

    8.  
    9. Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Tighten the following to specification:

      No. 1 Bearing cap: 22 ft. lbs. (30 Nm)
       
      No. 3 Bearing cap: 80 inch lbs. (9 Nm)
       

    10.  

  12.  
  13. To install camshaft No. 2, perform the following:
    1. Apply a light coat of engine oil to the journal portion of the No. 2 camshaft.
    2.  
    3. Put the No. 2 camshaft on the cylinder head with the paint mark of the chain aligned with the timing mark on the camshaft timing sprocket.

      Click image to see an enlarged view

      Fig. Aligning No. 2 camshaft paint mark with the timing mark

    4.  
    5. While holding the No. 2 camshaft by hand, temporarily tighten the camshaft timing sprocket set bolt.
    6.  
    7. Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head.

      Click image to see an enlarged view

      Fig. Checking the No. 2 camshaft bearing cap front marks, numbers and order

    8.  
    9. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

      Click image to see an enlarged view

      Fig. No. 2 camshaft bearing cap tightening sequence

    10.  
    11. Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Tighten the following to specification:

      No. 1 Bearing cap: 22 ft. lbs. (30 Nm)
       
      No. 3 Bearing cap: 80 inch lbs. (9 Nm)
       

    12.  
    13. While holding the camshaft with a wrench, tighten the camshaft timing sprocket set bolt and tighten to 40 ft. lbs. (54 Nm).

      Click image to see an enlarged view

      Fig. Aligning paint marks on the chain with the timing marks on the camshaft timing gear and camshaft timing sprocket

    14.  
    15. Check that the paint marks on the chain are aligned with the timing marks on the camshaft timing gear and camshaft timing sprocket. Also, check that the crankshaft pulley groove is aligned with the timing mark -0- of the timing chain cover.
    16.  

  14.  
  15. To complete installation, reverse remaining removal procedure.
  16.  
  17. Check engine for oil leaks.
  18.  
  19. Connect the negative battery cable.
  20.  

 
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