Scion 2005-06

Camshaft, Bearings & Lifters

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Inspection



Cam Height
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the camshafts.
  4.  
  5. Measure the cam height with a micrometer.
  6.  
  7. The intake camshaft should measure as follows:
    1. 1.5L Engine: between 1.7566-1.7605 inches (44.617-44.717 mm) and not less than 1.7508 inches (44.470 mm).
    2.  
    3. 2.4L Engine: between 1.8305-1.8345 inches (46.495-46.595 mm) and not less than 1.8262 inches (46.385 mm).
    4.  

  8.  
  9. The exhaust camshaft should measure as follows:
    1. 1.5L Engine: between 1.7585-1.7624 inches (44.666-44.766 mm) and not less than 1.7528 inches (44.520 mm).
    2.  
    3. 2.4L Engine: between 1.8104-1.8143 inches (45.983-46.083 mm) and not less than 1.8060 inches (45.873 mm).
    4.  

  10.  
  11. Camshaft should be replaced if it exceeds the limit.
  12.  

Camshaft End Play
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Install a dial indicator in the thrust direction on the front end of the camshaft. Measure the end play of the dial indicator when the camshaft is moved back and forth. The dial indicator should measure as follows:
    1. 1.5L Engine: between 0.0016-0.0037 inches (0.040-0.095 mm) and not exceed 0.0043 inches (0.11 mm).
    2.  
    3. 2.4L Engine: Intake camshaft between 0.0016-0.0037 inches (0.040-0.095 mm) and not exceed 0.0043 inches (0.11 mm). Exhaust camshaft between 0.0032-0.0053 inches (0.080-0.135 mm) and not exceed 0.0059 inches (0.15 mm).
    4.  

  4.  
  5. Replace the cylinder head assembly if the measurement is exceeded. Replace the camshaft if damage is found on the thrust surfaces.

    Click image to see an enlarged view

    Fig. Measuring for camshaft endplay

  6.  

Camshaft Runout
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the camshafts.
  4.  
  5. Place the camshaft on a V-block, on a precise flat table.
  6.  
  7. Set the dial indicator to center journal.
  8.  
  9. Turn the camshaft to one direction by hand and measure the camshaft runout.
  10.  
  11. Runout should measure less than 0.0012 inches (0.03 mm).
  12.  
  13. Camshaft should be replaced if it exceeds the limit.
  14.  

Journal Oil Clearance
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the camshafts.
  4.  
  5. Clean the 10 bearing caps and camshaft journals.
  6.  
  7. Place the 2 camshafts on the cylinder head.
  8.  
  9. Lay a strip of Plastigage® across each of the camshaft journals.
  10.  
  11. Install the 10 bearing caps.
    NOTE
    Do not turn the camshaft.

  12.  
  13. Remove the 10 bearing caps.
  14.  
  15. Measure the Plastigage® at its widest point.
  16.  
  17. Oil clearance should measure as follows:
    1. 1.5L Engine: All other journals should measure between 0.0016-0.0037 inches (0.040-0.095 mm). If any clearance measurement is more than 0.0045 inches (0.115 mm), the camshaft or cylinder head and bearing caps together (or both) need to be replaced.
    2.  
    3. 2.4L Engine: No. 1 intake journal should measure between 0.0003-0.0015 inches (0.007-0.038 mm). No. 1 exhaust journal should measure between 0.0016-0.0031 inches (0.040-0.079 mm). All other journals should be between 0.0010-0.0024 inches (0.025-0.062 mm). If any clearance measurement is more than 0.0028 inches (0.07 mm) for the No. 1 intake journal, or more than 0.0039 inches (0.10 mm) for all other journals, the camshaft or cylinder head sub-assembly (or both) needs to be replaced. If the No. 1 journal clearance is greater than the maximum, replace the bearing cap.
    4.  

  18.  

Removal & Installation



1.5L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Air intake assembly
     
    Engine appearance cover
     
    Right-hand front wheel
     
    Engine undercover
     
    Accelerator control cable
     
    Fuel tube from the fuel supply hose
     
    Brake booster check valve hose
     
    Radiator hose
     
    Heater hoses
     
    Radiator filler hose
     
    Front exhaust pipe
     
    Exhaust manifold
     
    Intake manifold
     
    Oil dipstick guide
     
    Ignition coil
     
    Accessory drive belts
     
    Alternator
     
    Camshaft timing oil control valve
     
    Ventilation hoses from the cylinder head cover
     
    Cylinder head cover
     
    Water pump
     
    Front cover
     
    Crankshaft pulley
     
    Crankshaft position sensor
     

  10.  
  11. Support the engine with a suitable jack.
  12.  
  13. Remove or disconnect the following:

    Right-hand engine mount
     
    Timing chain
     
    Fuel supply hose
     
    Fuel rail and injectors
     

  14.  
  15. In several passes, uniformly loosen and remove the camshaft bearing cap bolts in the sequence shown.
  16.  
  17. Remove the bearing caps and camshafts.
  18.  
  19. Remove the valve lifters.
    NOTE
    Keep all valvetrain components in order for reassembly.



    Click image to see an enlarged view

    Fig. Camshaft bearing cap bolt removal sequence-1.5L Engine

  20.  

To install:

  1. Apply a light coat of clean engine oil to each valve lifter.
  2.  
  3. Install the valve lifters.
    NOTE
    Ensure that each lifter rotates smoothly by hand.

  4.  
  5. Apply a light coat of clean engine oil to the camshaft journals.
  6.  
  7. Place the camshaft on the cylinder head with the timing mark on the camshaft gear facing upward.
  8.  
  9. Tighten the camshaft intake and exhaust bearing cap bolts in sequence to 9 ft. lbs. (13 Nm).
  10.  
  11. Install the No. 1 bearing cap and tighten to 17 ft. lbs. (23 Nm).

    Click image to see an enlarged view

    Fig. Camshaft bearing cap bolt torque sequence-1.5L Engine

  12.  
  13. The remainder of the installation is the reverse order of removal.
  14.  
  15. Refill the engine with oil to the correct level.
  16.  
  17. Refill the cooling system to the correct level.
  18.  
  19. Start the engine and check for leaks.
  20.  

2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Right-hand front wheel
     
    Engine undercover
     
    Right-hand front fender apron
     
    Engine appearance cover
     
    Wiper arm assembly
     
    Top cowl seal
     
    Left-hand top cowl ventilator louver
     
    Wiper linkage assembly
     
    Top outer cowl panel
     
    Left-hand cowl body mounting bracket
     
    Air intake assembly
     
    Throttle body
     
    Fuel rail
     
    Intake manifold
     
    Front exhaust pipe
     
    Oil dipstick guide
     
    Exhaust manifold
     
    Accessory drive belts
     
    Alternator
     
    Power steering pump
     

  10.  
  11. Support the engine with a suitable jack.
  12.  
  13. Remove or disconnect the following:

    Right-hand engine mount
     
    Ignition coil
     
    Cylinder head cover
     
    Accessory drive belt tensioner
     
    Crankshaft position sensor
     
    Oil pan
     

  14.  
  15. Turn the crankshaft pulley until its groove and the timing mark on the front cover are aligned to set the No. 1 cylinder to TDC.
  16.  
  17. Matchmark the timing chain and camshaft sprockets.
  18.  
  19. Holding the exhaust camshaft with a wrench, loosen the camshaft timing set bolt.
  20.  
  21. Using several steps, loosen the bearing cap bolts in the sequence shown. Remove the bearing caps.
  22.  
  23. Remove the camshaft timing set bolt while holding the exhaust camshaft in place.
  24.  
  25. Remove the exhaust camshaft, leaving the camshaft sprocket wrapped in the timing chain.
  26.  
  27. Remove the camshaft sprocket.

    Click image to see an enlarged view

    Fig. Match the groove on the crankshaft pulley to the front cover timing mark. Place matchmarks on the camshaft sprocket and timing chain-2.4L Engine



    Click image to see an enlarged view

    Fig. Secure the camshaft with a wrench when removing the set bolt-2.4L Engine



    Click image to see an enlarged view

    Fig. Exhaust camshaft bearing cap bolt removal sequence-2.4L Engine

  28.  
  29. Holding the intake camshaft with a wrench, loosen the camshaft timing set bolt.
  30.  
  31. Using several steps, loosen the intake camshaft bearing cap bolts in the sequence shown. Remove the bearing caps.
  32.  
  33. Remove the intake camshaft, with sprocket attached, while holding the timing chain by hand.
  34.  
  35. Secure the timing chain with string to prevent it from falling down into the front cover.

    Click image to see an enlarged view

    Fig. Intake camshaft bearing cap bolt removal sequence-2.4L Engine



    Click image to see an enlarged view

    Fig. Secure the timing chain with string after camshafts are removed-2.4L Engine

  36.  
  37. Remove the valve lifters.
    NOTE
    Keep all valvetrain components in order for reassembly.

  38.  

To install:

  1. Apply a light coat of clean engine oil to each valve lifter.
  2.  
  3. Install the valve lifters in their original places.
  4.  
  5. Apply a light coat of clean engine oil to the journals of the camshafts.
  6.  
  7. Install the camshafts on the cylinder head with the No. 1 cam lobes facing the directions shown.

    Click image to see an enlarged view

    Fig. Ensure the No. 1 cam lobes are facing the correct direction during installation-2.4L Engine

  8.  
  9. Examine the camshaft markings to ensure correct orientation of the camshafts for installation.

    Click image to see an enlarged view

    Fig. Compare the markings on the camshafts to the illustration for correct installation orientation-2.4L Engine

  10.  
  11. Apply a light coat of clean engine oil to the threads and under the heads of the bearing cap bolts.
  12.  
  13. Tighten the bearing cap bolts in sequence using the following torque values:
    1. No. 1 and No. 2 bearing cap to 22 ft. lbs. (30 Nm).
    2.  
    3. Remaining bolts to 80 inch lbs. (9 Nm).

      Click image to see an enlarged view

      Fig. Camshaft bearing cap bolt torque sequence-2.4L Engine

    4.  

  14.  
  15. The remainder of the installation is the reverse order of removal.
  16.  
  17. Refill the engine with oil to the correct level.
  18.  
  19. Refill the cooling system to the correct level.
  20.  
  21. Start the engine and check for leaks.
  22.  

 
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