Toyota Avalon, Camry, Camry Solara 2001-06

Camshaft, Bearings & Lifters 1

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Inspection



Camshaft End Play
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. This procedure is performed with the camshaft installed.
  4.  
  5. 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. 2.4L (2AZ-FE) Engine: Intake camshaft between 0.0016-0.0043 inches (0.040-0.110 mm). Exhaust camshaft between 0.0032-0.0059 inches (0.080-0.150 mm).
    2.  
    3. 1MZ-FE/3.3L (3MZ-FE) Engines: between 0.0016-0.0047 inches (0.040-0.120 mm).
    4.  
    5. 3.5L (2GR-FE) Engine: between 0.0031-0.0051 inches (0.080-0.130 mm).
    6.  

  6.  
  7. 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

  8.  

Camshaft Journal 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 bearing caps.
  14.  
  15. Measure the Plastigage® at its widest point.
  16.  
  17. Oil clearance should measure as follows:
    1. 2.4L (2AZ-FE) Engine: Intake No. 1 journal should measure between 0.0003-0.0028 inches (0.007-0.070 mm). Exhaust No. 1 journal should measure between 0.0016-0.0039 inches (0.040-0.100 mm). All other journals should be between 0.0010-0.0039 inches (0.025-0.100 mm). If any clearance measurement is more than 0.039 inches (0.10 mm), the camshaft or cylinder head (or both) needs to be replaced.
    2.  
    3. 1MZ-FE/3.3L (3MZ-FE) Engine: clearance should measure between 0.0010-0.0039 inches (0.025-0.100 mm). If any clearance measurement is more than the maximum, the camshaft or cylinder head and bearing caps, need to be replaced.
    4.  
    5. 3.5L (2GR-FE) Engine: No. 1 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 the maximum, the camshaft or camshaft housing (or both) needs to be replaced.
    6.  

  18.  

Removal & Installation



1MZ-FE Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    The thrust clearance on both the intake and exhaust camshafts is very small; the camshafts must be kept level during removal. If the camshafts are removed without being kept level, the camshaft may be caught in the cylinder head, causing the head to break or the camshaft to seize.



    Timing belt and idler pulley
     
    Camshaft timing pulleys
     
    Cylinder head covers
     

  4.  
  5. Remove the exhaust and intake camshafts from the right side cylinder head, as follows:
    1. Turn the camshaft with a wrench until the 2 pointed marks on the drive and driven gears are aligned. (The right camshaft gears have 2 marks apiece; the left side camshaft gears have 1 mark each.)
    2.  
    3. Secure the exhaust camshaft sub-gear to the main gear using a service bolt. A bolt 0.63-0.79 in. (16-20mm) long with a 6mm thread diameter and a 1mm pitch is recommended. When removing the exhaust camshaft be sure the sub-gear is not loaded; all the force must be eliminated.
    4.  
    5. Uniformly loosen and remove the exhaust camshaft bearing cap bolts in several passes and in the proper sequence. Remove the 8 bearing cap bolts and remove the caps, keeping them in the correct order.
    6.  
    7. Remove the exhaust camshaft from the engine.
    8.  
    9. Uniformly loosen and remove the 10 bearing cap bolts in several passes, in the proper sequence. Remove the bearing caps, keeping them in order, remove the oil seal, then, lift out the intake camshaft.
    10.  

  6.  
  7. Remove the exhaust and intake camshafts from the left side cylinder head, as follows:
    1. Turn the camshaft with a wrench until the pointed marks on the drive and driven gears are aligned. (The right camshaft gears have 2 marks apiece; the left side camshaft gears have 1 mark each.)
    2.  
    3. Secure the exhaust camshaft sub-gear to the main gear using a service bolt. A bolt 0.63-0.79 in. (16-20mm) long with a 6mm thread diameter and a 1mm pitch is recommended. When removing the exhaust camshaft be sure the sub-gear is not loaded; all the force must be eliminated.
    4.  
    5. Uniformly loosen and remove the exhaust camshaft bearing cap bolts in several passes and in the proper sequence. Remove the 8 bearing cap bolts and remove the caps. Keep the caps in the correct order.
    6.  
    7. Remove the exhaust camshaft from the engine.
    8.  
    9. Uniformly loosen and remove the 10 bearing cap bolts in several passes, in the reverse order of the installation sequence. Remove the bearing caps, keeping them in order, remove the oil seal, and then lift out the intake camshaft.
    10.  

  8.  
  9. Remove the valve lifter shims and hydraulic lifters. If the lifters are to be reused, store them upside down in a sealed container.
  10.  

To install:

Click image to see an enlarged view

Fig. Aligning the camshaft gear timing marks for the right camshafts-3.0L (1MZ-FE) engine



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Fig. Camshaft installation for the right exhaust camshaft-3.0L (1MZ-FE) engine



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Fig. Bearing cap bolt tightening sequence for the right exhaust camshaft-3.0L (1MZ-FE) engine



Click image to see an enlarged view

Fig. Bearing cap bolt tightening sequence for the right intake camshaft-3.0L (1MZ-FE) engine



Click image to see an enlarged view

Fig. Bearing cap bolt tightening sequence for the left exhaust camshaft-3.0L (1MZ-FE) engine



Click image to see an enlarged view

Fig. Bearing cap bolt tightening sequence for the left intake camshaft-3.0L (1MZ-FE) engine

  1. Install the valve lifters into their original positions and shims. Check the valve clearance and replace the shims as necessary.
    NOTE
    Before installing the camshafts in either cylinder head, apply multi-purpose grease to each camshaft.

  2.  
  3. Install the right camshafts, as follows:
    1. Position the intake camshaft on the head so that the alignment marks are at a 90 degrees angle from vertical. The mark should be at the -3 o'clock- position.
    2.  
    3. Apply sealant to the No. 1 bearing cap.
    4.  
    5. Apply a light coat of clean engine oil to the bolt threads and under the bolt head. Install the bearing caps to their proper position. Tighten the bolts evenly and in several passes to 12 ft. lbs. (16 Nm) in the proper sequence.
    6.  
    7. Position the exhaust camshaft on the head so that the alignment marks are at a 90 degrees angle from vertical. The mark must align with the marks on the other gear.
    8.  
    9. Apply a light coat of clean engine oil to the bolt threads and under the bolt head. Install the bearing caps to their proper position. Tighten the bolts evenly and in several passes to 12 ft. lbs. (16 Nm) in the proper sequence.
    10.  
    11. Remove the service bolt.
    12.  

  4.  
  5. Install the left camshaft, as follows:
    1. Position the intake camshaft on the head so that the alignment mark is at a 90degrees angle from vertical. The mark should be at the "9 o'clock'' position.
    2.  
    3. Apply sealant to the No. 1 bearing cap.
    4.  
    5. Apply a light coat of clean engine oil to the bolt threads and under the bolt head. Install the bearing caps to their proper position. Tighten the bolts evenly and in several passes to 12 ft. lbs. (16 Nm) in the proper sequence.
    6.  
    7. Position the exhaust camshaft on the head so that the alignment marks are at a 90 degree angle from vertical. The mark should be at the "3 o'clock'' position and must align with the marks on the other gear.
    8.  
    9. Apply a light coat of clean engine oil to the bolt threads and under the bolt head. Install the bearing caps to their proper position. Tighten the bolts evenly and in several passes to 12 ft. lbs. (16 Nm) in the proper sequence.
    10.  
    11. Remove the service bolt.
    12.  

  6.  
  7. Apply multi-purpose grease to new camshaft oil seals. Install the seals.
  8.  
  9. Install or connect the following:

    No. 3 (rear) timing belt cover
     
    Camshaft timing gears
     
    Idler pulley, timing belt and covers
     
    Cylinder head (valve) covers
     

  10.  

2az-FE Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Right-side front wheel
     
    Right-side fender apron
     
    Engine appearance cover
     
    Spark plug
     
    Ventilation hoses
     
    Engine wire
     
    Cylinder head cover
     

  4.  
  5. Turn the crankshaft clockwise and set the No. 1 cylinder at Top Dead Center (TDC) compression. Ensure the timing marks on the camshaft sprockets line up with the timing marks on the No. 1 bearing caps.
  6.  
  7. Place a paint mark on the timing chain to indicate TDC.
  8.  
  9. Remove the chain tensioner.
  10.  
  11. Hold the exhaust camshaft with a wrench, then loosen the sprocket bolt.
  12.  
  13. Uniformly remove the exhaust camshaft bearing cap bolts.
  14.  
  15. Remove the bearing caps.
  16.  
  17. Remove the exhaust camshaft sprocket from the timing chain and remove the camshaft.
  18.  
  19. Uniformly loosen and remove the intake camshaft bearing cap bolts.
  20.  
  21. Remove the bearing caps.
  22.  
  23. Remove the timing chain from the timing gear of the camshaft. Tie the timing chain with string so it does not fall into the front cover.
  24.  
  25. Remove the intake camshaft.

    Click image to see an enlarged view

    Fig. Place a paint mark on the timing chain, aligned with the timing marks already on the camshafts.-2.4L (2AZ-FE) engine

  26.  

To install:

  1. Install the timing chain on the intake camshaft timing gear, with the painted mark of the link aligned with the timing marks of the camshaft timing sprocket.
  2.  
  3. Install the intake bearing caps and tighten in the sequence shown as follows:
    1. Bearing cap No. 1: 22 ft. lbs. (30 Nm).
    2.  
    3. All others: 80 inch lbs. (9 Nm).

      Click image to see an enlarged view

      Fig. Intake camshaft bearing cap torque sequence-2.4L (2AZ-FE) engine

    4.  

  4.  
  5. Put the camshaft on the cylinder head with the painted mark of the link of chain aligned with the timing mark of the camshaft timing sprocket.
  6.  
  7. Raising the camshaft, temporarily tighten the sprocket bolt.
  8.  
  9. Install the exhaust bearing caps and tighten in the sequence shown as follows:
    1. Bearing cap No. 2: 22 ft. lbs. (30 Nm).
    2.  
    3. All others: 80 inch lbs. (9 Nm).

      Click image to see an enlarged view

      Fig. Exhaust camshaft bearing cap torque sequence-2.4L (2AZ-FE) engine

    4.  

  10.  
  11. Hold the camshaft with a wrench and tighten the sprocket bolt to 40 ft. lbs. (54 Nm).
  12.  
  13. Ensure all of the timing marks are aligned.
  14.  
  15. Install or connect the following:

    Chain tensioner
     
    Cylinder head cover. Tighten to 8 ft. lbs. (11 Nm).
     
    Engine wire
     
    Spark plug
     
    Engine appearance cover
     
    Fender apron
     
    Front wheel
     
    Negative battery cable
     

  16.  
  17. Start the engine and check for leaks.
  18.  

2gr-FE Engine


Click image to see an enlarged view

Fig. Exploded view of the camshaft components-3.5L (2GR-FE) 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. Remove or disconnect the following:

    Engine/transaxle assembly
     
    Engine wire
     
    Front frame assembly for the engine
     
    Starter
     
    Transaxle assembly from the engine
     
    Oil dipstick tube
     
    Exhaust manifolds
     
    Drive plate
     

  8.  
  9. Secure the engine in a suitable engine stand.
  10.  
  11. Remove or disconnect the following:

    Idler pulley
     
    Right-side engine mounting bracket
     
    Accessory drive belt tensioner
     
    No. 2 timing gear cover
     
    Right-side engine mounting stay and bracket
     
    Water inlet housing
     
    Crankshaft pulley
     
    Lower oil pan
     
    Oil strainer
     
    Upper oil pan
     
    Intake air surge tank
     
    Ignition coils
     
    Oil pipes
     
    Cylinder head cover
     
    Front cover and seal
     

  12.  
  13. Turn the crankshaft clockwise and set the No. 1 cylinder at Top Dead Center (TDC) compression.
  14.  
  15. Remove the No. 1 chain tensioner.
  16.  
  17. Remove the timing chain.
    WARNING
    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, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break.

  18.  
  19. While raising the chain tensioner No.2, insert a pin into the hole to fix it.
  20.  
  21. Holding the hexagonal portion of the exhaust camshaft with a wrench, remove the timing gear set bolt.
  22.  
  23. Separate the camshaft timing gears from the chain.
  24.  
  25. Remove the chain tensioner No. 2 and mounting bolt.
  26.  
  27. Remove the bearing cap gaskets.
  28.  
  29. Ensure the knock pin of the camshafts are positioned as shown.

    Click image to see an enlarged view

    Fig. The knock pins of the right side camshafts should be positioned as shown during removal and installation-3.5L (2GR-FE) engine



    Click image to see an enlarged view

    Fig. The knock pins of the left side camshafts should be positioned as shown during removal and installations-3.5L (2GR-FE) engine

  30.  
  31. Uniformly loosen and remove the first 8 bearing cap bolts in the sequence shown
    NOTE
    Matchmark the bearing caps for installation purposes.



    Click image to see an enlarged view

    Fig. Removal sequence of the first 8 bearing cap bolts-Right side 3.5L (2GR-FE) engine



    Click image to see an enlarged view

    Fig. Removal sequence of the first 8 bearing cap bolts-Left side 3.5L (2GR-FE) engine

  32.  
  33. Using several steps, loosen and remove the remaining 12 bearing cap bolts and remove the bearing caps.

    Click image to see an enlarged view

    Fig. Removal sequence of the remaining 12 bearing cap bolts-Right side 3.5L (2GR-FE) engine



    Click image to see an enlarged view

    Fig. Removal sequence of the remaining 12 bearing cap bolts-Right side 3.5L (2GR-FE) engine

  34.  
  35. Remove the camshafts.
  36.  

To install:

  1. Apply clean engine oil to the cam lobes and cylinder head journals.
  2.  
  3. Install the camshafts to the camshaft housing.
    NOTE
    Before and after setting the camshaft and No.2 camshaft, check that the rocker arm is firmly set to the lash adjuster.

  4.  
  5. Apply clean engine oil to the camshaft journal, camshaft housing and bearing cap.
  6.  
  7. Make sure of the marks and numbers on the camshaft bearing caps an place them in each proper position and direction.
  8.  
  9. Using several steps, install and temporarily tighten the first 8 bearing cap bolts uniformly in the reverse order of the removal sequence to 7 ft. lbs. (10 Nm).
  10.  
  11. Tighten the remaining 12 bearing cap bolts in the reverse order of removal to 18 ft. lbs. (25 Nm).
  12.  
  13. Using several steps, tighten the first 8 bearing cap bolts uniformly in the reverse order of the removal sequence to 12 ft. lbs. (16 Nm).
  14.  
  15. Install three new bearing cap gaskets.
  16.  
  17. Install the chain tensioner No.2 and tighten to 15 ft. lbs. (21 Nm).
  18.  
  19. While compressing the tensioner, insert a pin into the hole to fix it.
  20.  
  21. Align the mark links (yellow) with the timing marks of the camshaft timing gears as shown in the illustration.

    Click image to see an enlarged view

    Fig. Timing marks of the No. 2 timing chain-3.5L (2GR-FE) engine

  22.  
  23. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear RH with the No.2 chain installed.
  24.  
  25. Hold the camshaft with a wrench and tighten the sprocket bolts to 74 ft. lbs. (100 Nm).
  26.  
  27. Remove the pin from the tensioner.
  28.  
  29. The remainder of the installation is the reverse order of removal.
  30.  
  31. Refill the engine with oil to the correct level.
  32.  
  33. Refill the cooling system to the correct level.
  34.  
  35. Start the engine and check for leaks.
  36.  

3MZ-FE Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Align the camshaft pulleys so that they can be returned to the original locations when reassembling.


    WARNING
    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, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break.



    Negative battery cable
     
    RH front wheel
     
    Front suspension upper brace center
     
    V-bank cover sub-assembly
     
    Air cleaner assembly
     
    Emission control valve set
     
    Intake air surge tank
     
    Ignition coil assembly
     
    Cylinder head valve covers
     
    Front fender apron seal
     
    A/C Compressor and PS drive belts
     
    Engine stabilizing rod
     
    Engine mounting stay
     
    Alternator bracket
     
    Crankshaft pulley
     
    Timing belt covers
     
    Timing belt, tensioners, idlers and guides
     
    Camshaft timing pulleys
     



    Inner timing belt cover
     

  6.  
  7. Remove the camshaft using the following procedures
  8.  
  9. RH bank camshaft No.1 & LH bank camshaft No.2
    1. Align the (2 dot marks) of the camshaft drive and driven gear by turning the camshaft with a wrench.

      Click image to see an enlarged view

      Fig. Aligning timing marks-3.3L (3MZ-FE) engine

    2.  
    3. Secure the exhaust camshaft sub gear to the main gear with service bolt. Torque to 48 inch lbs. (5.4 Nm).
      NOTE
      When removing the camshaft, make certain that the torsional spring force of the sub gear has been eliminated by installation of the service bolt.

    4.  
    5. Using several steps, loosen the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and camshaft
      WARNING
      Do not pry out camshaft


      WARNING
      Do not damage contact surface of the cylinder head that receives the shaft thrust.



      Click image to see an enlarged view

      Fig. Camshaft bolt removal sequence Camshaft No.1-3.3L (3MZ-FE) engine



      Click image to see an enlarged view

      Fig. Camshaft bolt removal sequence Camshaft No.2 -3.3L (3MZ-FE) engine

    6.  

  10.  
  11. LH bank camshaft No. 3 & No. 4
    1. Using several steps, loosen the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and camshaft
      WARNING
      Do not pry out camshaft


      WARNING
      Do not damage contact surface of the cylinder head that receives the shaft thrust.



      Click image to see an enlarged view

      Fig. Camshaft bolt removal sequence camshaft No. 3-3.3L (3MZ-FE) engine



      Click image to see an enlarged view

      Fig.

    2.  
    3. Remove the oil seal from camshaft
    4.  

  12.  

To install:

  1. Install RH No 2 Camshaft then RH Camshaft No. 1 using same procedure
    WARNING
    Since the clearance of the camshaft is small, the camshaft must be kept level while bring installed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged.

    1. Apply engine oil to the thrust portion and journal of camshaft
    2.  
    3. No. 2 camshaft at 90 degree angel to the timing mark (2 dot marks) on the head.
    4.  
    5. Multi-purpose grease to new oil seal
    6.  
    7. Oil seal to camshaft
      NOTE
      Do NOT turn over the oil seal lip


      NOTE
      Insert oil seal until it stops

    8.  
    9. Seal packing to bearing cap No. 1
      NOTE
      Install bearing cap No. 1 within 5 minutes after applying seal packing


      NOTE
      Do NOT expose seal packing to engine oil within 2 hours after installation

    10.  
    11. 5 bearing caps in their proper locations
    12.  
    13. Apply light coat of oil to the threads of the bearing caps
    14.  
    15. Tighten the 10 bearing cap bolts in required sequence. Torque to: 12 ft. lbs. (16 Nm)
    16.  

  2.  
  3. Install LH camshaft No.3 and LH camshaft No. 4 using the above procedure

    Click image to see an enlarged view

    Fig. Bolt torque procedure RH camshaft No. 2-3.3L (3MZ-FE) engine



    Click image to see an enlarged view

    Fig. Bolt torque procedure RH camshaft No. 1-3.3L (3MZ-FE) engine



    Click image to see an enlarged view

    Fig. Bolt torque procedure LH camshaft No. 3-3.3L (3MZ-FE) engine



    Click image to see an enlarged view

    Fig. Bolt torque procedure LH camshaft No. 4-3.3L (3MZ-FE) engine

  4.  
  5. Install or connect the following:

    Inner timing belt cover
     
    RH then LH camshaft timing pulleys. Torque to: 92 ft. lbs. (125 Nm)
     
    Timing belt idlers, tensioners, guide and belt
     
    RH engine mounting bracket
     
    Timing belt covers
     
    Crankshaft pulley
     
    Alternator bracket
     
    RH engine mounting stay
     
    Engine stabilizing rod
     
    Inspect or adjust valve lash
     
    A/C compressor and PS drive belts
     
    Cylinder head valve covers
     
    Ignition coil assembly
     
    Intake air surge tank
     
    Emission control valve set
     
    Air cleaner assembly
     
    Vacuum hoses
     
    V-bank cover sub-assembly
     
    Front suspension upper center brace
     
    RF wheel
     
    Negative battery cable
     

  6.  
  7. Refill the cooling system to the correct level.
  8.  
  9. Start the engine and check for leaks.
  10.  

 
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