Lexus Car ES, IS, LS 1998-06

Camshaft, Bearings & Lifters 5

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Removal & Installation



4.3L (3UZ-FE) Engines (2004)
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel pressure from the fuel lines.
  4.  
  5. Remove or disconnect the following:

    Engine under cover
     
    Drain engine coolant and engine oil
     
    V-bank cover
     
    Air cleaner assembly
     
    Intake air pipe
     
    Radiator
     
    Throttle body
     
    Upper and lower intake manifold assembly
     
    Timing belt from camshaft pulleys
     
    Camshaft position sensor and LH timing belt rear plates
     
    RH timing belt rear plates
     

  6.  


WARNING
Do NOT drop anything inside timing belt cover during this procedure. Keep oil, water and dust from timing belt.



Power steering pump from engine mount (Do NOT disconnect hoses)
 
Catalytic converters
 
Water inlet housing assembly
 
Water bypass pipe, front bypass joint, and rear bypass joint
 
Ignition coils
 
Variable valve timing (VVT) sensors
 
Engine hangers
 
Oil dipsticks and guides for engine oil and transmission fluid
 
Cylinder head covers
 
Spark plugs
 
Semi-circular plugs and camshaft housing plugs
 
Camshaft timing oil control valve
 


WARNING
Since the thrust clearance of the camshaft is small, the camshaft must be kept level during removal steps. If it is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to later seize or break. Follow the procedure carefully to avoid this damage.

  1. Check the crankshaft pulley position and ensure the timing mark of the pulley is aligned with the centers of the crankshaft pulley bolt and the No. 2 timing belt idler pulley bolt.
  2.  


WARNING
Having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other during camshaft removal. Always set the crankshaft pulley at the described angle.

  1. Using a special wrench, rotate the camshaft timing tube from left to right about 2-3 times, within only a 25°range of movement. Use a waste cloth to collect oil from the camshaft timing oil control valve installation hole.
  2.  
  3. Remove the LH camshafts first. With a hex wrench on the hex portion of the camshaft, rotate so that a 6mm service bolt can be inserted into the bolt hole in the rear face of the camshaft pulley into order to secure the camshaft in place. The bolt should be about 0.63-0.79 in. (16-20mm) long.
  4.  
  5. Align the timing mark (2 dots) of the camshaft drive gear by turning the camshaft with a hex wrench until the timing mark aligns.
  6.  
  7. Now, uniformly loosen the 22 camshaft bearing cap bolts, in several passes, following the sequence shown.
  8.  
  9. Remove the 22 bearing cap bolts, 4 seal washers, oil feed pipe, 9 bearing caps, the camshaft housing plug, the oil control valve filter, and both LH camshafts. Keep all parts in order for proper reinstallation.
  10.  
  11. Remove the RH camshafts. With a hex wrench on the hex portion of the camshaft, rotate so that a 6mm service bolt can be inserted into the bolt hole in the rear face of the camshaft pulley into order to secure the camshaft in place. The bolt should be about 0.63-0.79 in. (16-20mm) long.
  12.  
  13. Align the timing mark (1 dot) of the camshaft main gear about 10° angle by turning the camshaft with a hex wrench until the timing mark aligns.
  14.  
  15. Now, uniformly loosen the 22 camshaft bearing cap bolts, in several passes, following the sequence shown.
  16.  
  17. Remove the 22 bearing cap bolts, 4 seal washers, oil feed pipe, 9 bearing caps, the camshaft housing plug, the oil control valve filter, and both LH camshafts. Keep all parts in order for proper reinstallation.
  18.  


    Click image to see an enlarged view

    Fig. LH camshaft bearing cap bolt loosening sequence-4.3L (3UZ-FE) Engine (2004 Model)



    Click image to see an enlarged view

    Fig. RH camshaft bearing cap bolt loosening sequence-4.3L (3UZ-FE) Engine (2004 Model)


To install:


WARNING
Since the thrust clearance of the camshaft is small, the camshaft must be kept level during removal steps. If it is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to later seize or break. Follow the procedure carefully to avoid this damage.

  1. Ensure the crankshaft pulley is in position so that its timing mark is in line with the centers of the pulley bolt and idler pulley bolt.
  2.  


WARNING
Having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other during camshaft removal. Always set the crankshaft pulley at the described angle.

  1. Apply grease to the thrust portion of the LH intake and exhaust camshafts. Align the timing marks (2 dots) of the camshaft drive and driven main gears. Place the camshafts into the LH cylinder head.
  2.  
  3. Apply new seal packing material around the opening of the camshaft housing plug. Install the camshaft housing plug and the oil control valve filter into the cylinder head, as shown.
  4.  
  5. Remove any old packing material, then install new packing material around the mounting edge (not in the grooves) of the front bearing cap.
  6.  
  7. Position the front bearing cap in place. This will determine the thrust portion of the camshaft.
    1. Install the other bearing caps, in sequence shown, with the arrow marks facing forward.
    2.  
    3. Push the camshaft oil seal into place by pushing from the front of the engine. Install a new seal washer to the front bearing cap bolts.
    4.  
    5. Apply a light coat of oil to bearing cap bolt threads and under the heads of the bearing cap bolts -D- and -E-, as shown. Do NOT apply engine oil under the heads of bearing cap bolts -A-, -B- and -C-.
    6.  
    7. Bolt lengths vary for each bearing cap. Refer to the illustration for each of the following bolts:
    8.  
    9. Bolt -A- with seal washer is 3.70 in. (94mm)
    10.  
    11. Bolt -B- with seal washer is 2.83 in. (72mm)
    12.  
    13. Bolt -C- is 0.98 in. (25mm)
    14.  
    15. Bolt -D- is 2.05 in. (52mm)
    16.  
    17. Bolt -E- is 1.50 in. (38mm)
    18.  

  8.  
  9. Install the oil feed pipe and the 22 bearing cap bolts in their respective locations. Uniformly tighten the 22 bearing cap bolts, in several passes, following the sequence as shown. Torque bolt -C- to a final torque of 66 inch lbs. (7.5 Nm). Torque all other bearing cap bolts to a final torque of 12 ft. lbs. (16 Nm).
  10.  
  11. Remove the service bolt installed in the rear face of the gear.
  12.  
  13. Repeat this entire procedure for the RH camshafts. Use the illustrations given for the LH camshafts, as the sequences are the same on the RH camshafts.
  14.  
  15. Check and adjust valve lash. See VALVE LASH.
  16.  
  17. Install or reconnect the following:

    Camshaft timing oil control valve.
     
    Semi-circular plugs in rear ends of each cylinder head
     
    Cylinder head covers, with new gaskets and packing material
     
    Engine hangers
     
    Variable valve timing sensors
     
    Oil dipsticks and tubes
     
    All remaining components in reverse of removal procedure.
     

  18.  


    Click image to see an enlarged view

    Fig. Installing the camshaft housing plug and oil control valve filter for the LH camshaft-4.3L (3UZ-FE) Engine (2004 Model)



    Click image to see an enlarged view

    Fig. Installing the camshaft bearing caps in sequence on the LH camshaft-4.3L (3UZ-FE) Engine (2004 Model)



    Click image to see an enlarged view

    Fig. Identifying the locations of camshaft bearing caps on the LH camshaft-4.3L (3UZ-FE) Engine (2004 Model)



    Click image to see an enlarged view

    Fig. Identifying the locations of camshaft bearing caps on the LH camshaft-4.3L (3UZ-FE) Engine (2004 Model)


4.7L Engine
Left Side
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Remove cylinder head cover.
    WARNING
    When the timing chain is removed and the cylinder heads are still installed, DO NOT forcefully rotate the camshafts or crankshaft independently of each other. Severe valve and/or piston damage can occur.


    WARNING
    When removing the cam sprocket, timing chains or camshaft, failure to use Special Tool 8350 will result in hydraulic tensioner ratchet over extension, requiring timing chain cover removal to reset the tensioner ratchet.



    Click image to see an enlarged view

    Fig. Set engine to TDC cylinder no.1, camshaft sprocket V8 marks at the 12 o-clock position-4.7L engine

  4.  
  5. Set engine to TDC cylinder no.1, camshaft sprocket V8 marks at the 12 o-clock position.
  6.  
  7. Mark one link on the secondary timing chain on both sides of the V8 mark on the camshaft sprocket to aid in installation.
    WARNING
    Do not hold or pry on the camshaft target wheel (located on the right side camshaft sprocket) for any reason, severe damage will occur to the target wheel resulting in a vehicle no start condition.

  8.  
  9. Loosen but do not remove the camshaft sprocket retaining bolt. Leave the bolt snug against the sprocket.
    NOTE
    The timing chain tensioners must be secured prior to removing the camshaft sprockets. Failure to secure tensioners will allow the tensioners to extend, requiring timing chain cover removal in order to reset tensioners.


    WARNING
    Do not force wedge past the narrowest point between the chain strands. Damage to the tensioners may occur.



    Click image to see an enlarged view

    Fig. The timing chain tensioners must be secured prior to removing the camshaft sprockets-4.7L engine

  10.  
  11. Position Special Tool 8350 timing chain wedge between the timing chain strands, tap the tool to securely wedge the timing chain against the tensioner arm and guide.
    NOTE
    When gripping the camshaft, place the pliers on the tube portion of the camshaft only. Do not grip the lobes or the sprocket areas.



    Click image to see an enlarged view

    Fig. Hold the camshaft with adjustable pliers is the camshaft dowel-4.7L engine



    Click image to see an enlarged view

    Fig. Hold the left camshaft sprocket with a spanner wrench while removing he camshaft sprocket-4.7L engine



    Click image to see an enlarged view

    Fig. Camshaft bearing cap bolt tightening sequence-4.7L engine



    Click image to see an enlarged view

    Fig. Turn the camshaft with pliers, if needed, to align the dowel in the sprocket-4.7L engine

  12.  
  13. Hold the camshaft with adjustable pliers while removing the camshaft sprocket bolt and sprocket.
  14.  
  15. Using the pliers, gently allow the camshaft to rotate 15° clockwise until the camshaft is in the neutral position (no valve load).
  16.  
  17. Starting at the outside working inward, loosen the camshaft bearing cap retaining bolts 1 / 2 turn at a time. Repeat until all load is off the bearing caps.
    WARNING
    Do not stamp or strike the camshaft bearing caps. Severe damage will occur to the bearing caps.


    NOTE
    When the camshaft is removed the rocker arms may slide downward, mark the rocker arms before removing camshaft.

  18.  
  19. Remove the camshaft bearing caps and the camshaft.
  20.  

To install:

Click image to see an enlarged view

Fig. Camshaft tightening sequence-4.7L engine

  1. Lubricate camshaft journals with clean engine oil.
    NOTE
    Position the left side camshaft so that the camshaft sprocket dowel is near the 1 o-clock position. This will place the camshaft at the neutral position easing the installation of the camshaft bearing caps.

  2.  
  3. Position the camshaft into the cylinder head.
  4.  
  5. Install the camshaft bearing caps, hand tighten the retaining bolts.
  6.  
  7. Working in 1 / 2 turn increments, tighten the bearing cap retaining bolts starting with the middle cap working outward.
  8.  
  9. Torque the camshaft bearing cap retaining bolts to 100 inch lbs. (11 Nm).
  10.  
  11. Position the camshaft drive gear into the timing chain aligning the V8 mark between the two marked chain links (two links marked during removal).
    NOTE
    When gripping the camshaft, place the pliers on the tube portion of the camshaft only. Do not grip the lobes or the sprocket areas.

  12.  
  13. Using the adjustable pliers, rotate the camshaft until the camshaft sprocket dowel is aligned with the slot in the camshaft sprocket. Install the sprocket onto the camshaft.
    WARNING
    Remove excess oil from camshaft sprocket bolt. Failure to do so can cause bolt over-torque resulting in bolt failure.

  14.  
  15. Remove excess oil from bolt, then install the camshaft sprocket retaining bolt and hand tighten.
  16.  
  17. Remove Special Tool 8350 timing chain wedge.

    Click image to see an enlarged view

    Fig. Using Special Tool 6958 spanner wrench with adapter pins 8346, torque the camshaft sprocket retaining bolt is the torque wrench, is the head-4.7L engine

  18.  
  19. Using Special Tool 6958 spanner wrench with adapter pins 8346, torque the camshaft sprocket retaining bolt to 90 ft. lbs. (122 Nm).
  20.  
  21. Install the cylinder head cover.
  22.  

Right Side
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
    WARNING
    When the timing chain is removed and the cylinder heads are still installed, do not forcefully rotate the camshafts or crankshaft independently of each other. Severe valve and/or piston damage can occur.


    WARNING
    When removing the cam sprocket, timing chains or camshaft, failure to use special tool 8350 will result in hydraulic tensioner ratchet over extension, requiring timing chain cover removal to reset the tensioner ratchet.

  2.  
  3. Set engine to TDC cylinder no.1, camshaft sprocket V8 marks at the 12 o-clock position.
  4.  
  5. Mark one link on the secondary timing chain on both sides of the V8 mark on the camshaft sprocket to aid in installation.
    WARNING
    Do not hold or pry on the camshaft target wheel for any reason, severe damage will occur to the target wheel. A damaged target wheel could cause a vehicle no start condition.

  6.  
  7. Loosen but do not remove the camshaft sprocket retaining bolt. Leave bolt snug against sprocket.
    NOTE
    The timing chain tensioners must be secured prior to removing the camshaft sprockets. Failure to secure tensioners will allow the tensioners to extend, requiring timing chain cover removal in order to reset tensioners.


    WARNING
    Do not force wedge past the narrowest point between the chain strands. Damage to the tensioners may occur.

  8.  
  9. Position Special Tool 8350 timing chain wedge between the timing chain strands. Tap the tool to securely wedge the timing chain against the tensioner arm and guide.
  10.  
  11. Remove the camshaft position sensor.
    NOTE
    When gripping the camshaft, place the pliers on the tube portion of the camshaft only. Do not grip the lobes or the sprocket areas.

  12.  
  13. Hold the camshaft with adjustable pliers while removing the camshaft sprocket bolt and sprocket.
  14.  
  15. Using the pliers, gently allow the camshaft to rotate 45° counterclockwise until the camshaft is in the neutral position (no valve load).
  16.  
  17. Starting at the outside working inward, loosen the camshaft bearing cap retaining bolts 1 / 2 turn at a time. Repeat until all load is off the bearing caps.
    WARNING
    Do not stamp or strike the camshaft bearing caps. Severe damage will occur to the bearing caps.


    NOTE
    When the camshaft is removed the rocker arms may slide downward, mark the rocker arms before removing camshaft.

  18.  
  19. Remove the camshaft bearing caps and the camshaft.
  20.  

To install:

  1. Lubricate camshaft journals with clean engine oil.
    NOTE
    Position the right side camshaft so that the camshaft sprocket dowel is near the 10 o-clock position. This will place the camshaft at the neutral position easing the installation of the camshaft bearing caps.

  2.  
  3. Position the camshaft into the cylinder head.
  4.  
  5. Install the camshaft bearing caps, hand tighten the retaining bolts.
  6.  
  7. Working in 1 / 2 turn increments, tighten the bearing cap retaining bolts starting with the middle cap working outward.
  8.  
  9. Torque the camshaft bearing cap retaining bolts to 100 inch lbs.(11 Nm).
  10.  
  11. Position the camshaft drive gear into the timing chain aligning the V8 mark between the two marked chain links (two links marked during removal).
    NOTE
    When gripping the camshaft, place the pliers on the tube portion of the camshaft only. Do not grip the lobes or the sprocket areas.

  12.  
  13. Using the adjustable pliers, rotate the camshaft until the camshaft sprocket dowel is aligned with the slot in the camshaft sprocket. Install the sprocket onto the camshaft.
    WARNING
    Remove excess oil from camshaft sprocket bolt. Failure to do so can cause bolt over-torque resulting in bolt failure.

  14.  
  15. Remove excess oil from camshaft sprocket bolt, then install the camshaft sprocket retaining bolt and hand tighten.
  16.  
  17. Remove timing chain wedge special tool 8350.

    Click image to see an enlarged view

    Fig. Tightening the right side camshaft sprocket retaining bolt-4.7L engine

  18.  
  19. Using Special Tool 6958 spanner wrench with adapter pins 8346, torque the camshaft sprocket retaining bolt to 90 ft. lbs. (122 Nm).
  20.  
  21. Install the camshaft position sensor.
  22.  
  23. Install the cylinder head cover.
  24.  

 
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