Toyota Highlander 6 2001-06

Camshaft, Bearings & Lifters 1

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Inspection



Camshaft Runout
3.0L & 3.3L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the camshafts from the vehicle.
  4.  
  5. Place the camshaft on V-blocks
  6.  
  7. Using a dial indicator, measure the amount of runout at the center journal.
  8.  
  9. If the runout is greater than 0.0024 in. (0.06 mm), replace the camshaft.

    Click image to see an enlarged view

    Fig. Use a dial indicator to inspect the camshaft runout.

  10.  

Removal & Installation



2.4L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Remove or disconnect the following:

    Right front wheel
     
    Right fender splash shield
     
    Right fender apron seal
     
    No.1 engine undercover
     
    Coil pack
     
    Cylinder head cover
     

  8.  
  9. Set the No.1 piston at TDC compression.
  10.  
  11. Remove or disconnect the following:

    Timing chain tensioner No.1
     

  12.  
  13. Loosen the camshaft timing gear set bolt.
  14.  
  15. Raise the camshaft and remove the set bolt.

    Click image to see an enlarged view

    Fig. Exhaust camshaft cap bolt loosening sequence-2.4L Highlander

  16.  
  17. Remove or disconnect the following:

    Timing gear and chain
     
    Exhaust camshaft
     

  18.  
  19. Loosen the intake camshaft cap bolts in several passes, in the sequence shown. Remove the caps. Remove the camshaft.

    Click image to see an enlarged view

    Fig. Intake camshaft cap bolt loosening sequence-2.4L Highlander

  20.  
  21. Installation is the reverse of removal. Tighten the cap bolt, in several passes, in the sequences shown, to:

    Front caps: 22 ft. lbs. (30 Nm)
     
    All other caps: 80 inch lbs. (9 Nm)

    Click image to see an enlarged view

    Fig. Intake camshaft cap bolt tightening sequence-2.4L Highlander



    Click image to see an enlarged view

    Fig. Exhaust camshaft cap bolt tightening sequence-2.4L Highlander

     

  22.  
  23. See the Timing Chain Removal and Installation procedure.
  24.  

3.0L Engine
  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 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.

      Click image to see an enlarged view

      Fig. Right intake camshaft bearing cap bolt loosening sequence-3.0L engine



      Click image to see an enlarged view

      Fig. Right side exhaust camshaft bearing cap bolt loosening sequence-3.0L engine

    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 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, then lift out the intake camshaft.

      Click image to see an enlarged view

      Fig. Left intake camshaft bearing cap bolt loosening sequence-3.0L engine



      Click image to see an enlarged view

      Fig. Left side exhaust camshaft bearing cap bolt loosening sequence-3.0L engine

    10.  

  8.  
  9. Remove the valve lifter shims and hydraulic lifters. Identify each lifter and shim as it is removed so it can be reinstalled in the same position. If the lifters are to be reused, store them upside down in a sealed container.
  10.  

To install:

  1. Install the valve lifters into their original positions and install the shims. Check valve clearance and replace the shims as necessary.
  2.  
  3. When reinstalling, remember that the camshafts must be handled carefully and kept straight and level to avoid damage.

    Click image to see an enlarged view

    Fig. Right exhaust bearing caps must be placed in their proper locations-3.0L engine



    Click image to see an enlarged view

    Fig. Right exhaust camshaft bearing cap bolt tightening sequence-3.0L engine

  4.  
  5. Before installing the camshafts in either cylinder head, apply multi-purpose grease to each camshaft.
  6.  
  7. 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 should be at the "9 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.

      Click image to see an enlarged view

      Fig. Right intake bearing caps must be placed in their proper locations-3.0L engine



      Click image to see an enlarged view

      Fig. Right intake camshaft bearing cap bolt tightening sequence-3.0L engine

    12.  

  8.  
  9. Install the left camshafts, as follows:
    1. Position the intake camshaft on the head so that the alignment mark is at a 90 degrees 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 degrees 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.

      Click image to see an enlarged view

      Fig. Left exhaust bearing caps locations and bolt tightening sequence-3.0L engine



      Click image to see an enlarged view

      Fig. Left intake camshaft bearing cap locations and bolt tightening sequence-3.0L engine

    12.  

  10.  
  11. Install or connect the following:

    New camshaft oil seals, lubricated with multi-purpose grease
     
    No. 3 (rear) timing belt cover
     
    Camshaft timing gears
     
    Idler pulley, timing belt and covers
     

  12.  
  13. Check and adjust the valve clearance.
  14.  
  15. Install the cylinder head (valve) covers.
  16.  
  17. Start the engine. Check the ignition timing.
  18.  
  19. Test drive the vehicle.
  20.  
  21. Check all fluid levels.
  22.  

3.3L Engine
  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 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.

      Click image to see an enlarged view

      Fig. Right intake camshaft bearing cap bolt loosening sequence-3.3L engine



      Click image to see an enlarged view

      Fig. Right side exhaust camshaft bearing cap bolt loosening sequence-3.3L engine

    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 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, then lift out the intake camshaft.

      Click image to see an enlarged view

      Fig. Left intake camshaft bearing cap bolt loosening sequence-3.3L engine



      Click image to see an enlarged view

      Fig. Left side exhaust camshaft bearing cap bolt loosening sequence-3.3L engine

    10.  

  8.  
  9. Remove the valve lifter shims and hydraulic lifters. Identify each lifter and shim as it is removed so it can be reinstalled in the same position. If the lifters are to be reused, store them upside down in a sealed container.
  10.  

To install:

  1. Install the valve lifters into their original positions and install the shims. Check valve clearance and replace the shims as necessary.
  2.  
  3. When reinstalling, remember that the camshafts must be handled carefully and kept straight and level to avoid damage.

    Click image to see an enlarged view

    Fig. Right exhaust bearing caps must be placed in their proper locations-3.3L engine



    Click image to see an enlarged view

    Fig. Right exhaust camshaft bearing cap bolt tightening sequence-3.3L engines

  4.  
  5. Before installing the camshafts in either cylinder head, apply multi-purpose grease to each camshaft.
  6.  
  7. 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 should be at the "9 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.

      Click image to see an enlarged view

      Fig. Right intake bearing caps must be placed in their proper locations-3.3L engine



      Click image to see an enlarged view

      Fig. Right intake camshaft bearing cap bolt tightening sequence-3.3L engine

    12.  

  8.  
  9. Install the left camshafts, as follows:
    1. Position the intake camshaft on the head so that the alignment mark is at a 90 degrees 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 degrees 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.

      Click image to see an enlarged view

      Fig. Left exhaust bearing caps locations and bolt tightening sequence-3.3L engine



      Click image to see an enlarged view

      Fig. Left intake camshaft bearing cap locations and bolt tightening sequence-3.3L engine

    12.  

  10.  
  11. Install or connect the following:

    New camshaft oil seals, lubricated with multi-purpose grease
     
    No. 3 (rear) timing belt cover
     
    Camshaft timing gears
     
    Idler pulley, timing belt and covers
     

  12.  
  13. Check and adjust the valve clearance.
  14.  
  15. Install the cylinder head (valve) covers.
  16.  
  17. Start the engine. Check the ignition timing.
  18.  
  19. Test drive the vehicle.
  20.  
  21. Check all fluid levels.
  22.  

 
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