Toyota Highlander Hybrid 6 2005-06

Camshaft, Bearings & Lifters 2

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Removal & Installation



Hybrid

WARNING
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.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the coolant from the engine radiator and hybrid transaxle.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover
     
    Right-hand front wheel
     
    Engine splash shields
     
    Right-hand front fender apron seal
     
    Wiper and blade assembly
     
    Top cowl ventilator louver assembly
     
    Wiper motor and link assembly
     
    Battery and battery tray
     
    Air intake assembly
     
    Emission control valve hoses
     
    Air intake surge tank
     
    Radiator intake hose
     
    Brake master cylinder reservoir and bracket
     
    Air cleaner bracket
     
    Engine moving control rod
     
    Right-hand engine No.2 mounting stay
     
    Ignition coil
     
    Valve covers
     
    Crankshaft pulley
     
    Timing belt No.1 and No.2 covers
     
    Right-hand engine mounting bracket
     
    No.2 timing belt guide
     
    Timing belt
     
    Timing belt idler
     

  10.  
  11. Using Special Tool 09960-10010, remove the camshaft timing pulleys.
    NOTE
    Keep all valvetrain components in order for reassembly.



    Click image to see an enlarged view

    Fig. Removing the right-hand camshaft timing pulley, left-hand similar.

  12.  
  13. Disconnect the engine wiring harness clamps from the No.3 timing belt cover and remove the cover.
  14.  
  15. Remove the left camshafts as follows:
    1. Align the timing marks (2-dot mark) of the camshaft drive and the driven gears by turning the camshaft with a wrench.
    2.  
    3. Secure the exhaust camshaft sub-gear to the main gear with a service bolt. A bolt 0.63-0.79 in. (16-20mm) long with a 6mm thread diameter and a 1mm pitch is recommended. Tighten bolt 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 installing the service bolt.

    4.  
    5. Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown.
    6.  
    7. Remove the 5 bearing caps and the exhaust camshaft.
    8.  
    9. Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown.
    10.  
    11. Remove the 5 bearing caps and the intake camshaft.
    12.  
    13. Remove the oil seal from the intake camshaft.
    14.  

  16.  
  17. Repeat the same process to remove the right-side camshafts, beginning with the intake camshaft.

    Click image to see an enlarged view

    Fig. Align the timing marks of the camshaft gears.



    Click image to see an enlarged view

    Fig. Install a service bolt to secure the camshaft gears.



    Click image to see an enlarged view

    Fig. Intake camshaft bearing cap loosening sequence



    Click image to see an enlarged view

    Fig. Exhaust camshaft bearing cap loosening sequence

  18.  
  19. 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.
  20.  

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.
  4.  
  5. Install the right camshafts, as follows:
    1. Apply new engine oil to the thrust portion and journal of the camshaft.
    2.  
    3. Position the exhaust camshaft on the head so that the alignment marks are at a 90 degrees angle from vertical.
    4.  
    5. Apply multi-purpose grease to the lip of a new oil seal.
    6.  
    7. Install the oil seal to the camshaft.
    8.  
    9. Apply sealant to the No. 1 bearing cap.
    10.  
    11. 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.

      Click image to see an enlarged view

      Fig. Install the right exhaust camshaft with the alignment marks in the correct position.



      Click image to see an enlarged view

      Fig. Right exhaust camshaft bearing caps must be placed in their proper locations.



      Click image to see an enlarged view

      Fig. Right exhaust camshaft bearing cap torque sequence

    12.  
    13. 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 "9 o-clock" position and must align with the marks on the other gear.
    14.  
    15. 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.
    16.  
    17. Remove the service bolt.

      Click image to see an enlarged view

      Fig. Right intake camshaft bearing caps must be placed in their proper locations



      Click image to see an enlarged view

      Fig. Right intake camshaft bearing cap bolt tightening sequence

    18.  

  6.  
  7. Install the left camshafts, as follows:
    1. Apply new engine oil to the thrust portion and journal of the camshaft
    2.  
    3. Position the exhaust 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.
    4.  
    5. Apply multi-purpose grease to the oil seal lip and install the new oil seal to the camshaft.
    6.  
    7. Apply sealant to the No. 1 bearing cap.
    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.

      Click image to see an enlarged view

      Fig. Install the left exhaust camshaft with the alignment mark in the correct position.



      Click image to see an enlarged view

      Fig. Left exhaust camshaft bearing caps must be placed in their proper locations



      Click image to see an enlarged view

      Fig. Left exhaust camshaft bearing cap torque sequence

    10.  
    11. 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 and must align with the marks on the exhaust camshaft gear.
    12.  
    13. 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.
    14.  
    15. Remove the service bolt.

      Click image to see an enlarged view

      Fig. Install the left intake camshaft with the alignment mark in the correct position.



      Click image to see an enlarged view

      Fig. Left exhaust camshaft bearing caps must be placed in their proper locations.



      Click image to see an enlarged view

      Fig. Left exhaust bearing cap torque sequence

    16.  

  8.  
  9. Install or connect the following:


  10.  
  11. Install the timing belt cover No. 3. Tighten to 76 inch lbs. (8.5 Nm)
  12.  
  13. Using Special Tool 09960-10010, install the camshaft timing pulleys. Tighten to 92 ft. lbs. (125 Nm).
  14.  
  15. Install the timing belt idler and tighten to 32 ft. lbs. (43 Nm).
  16.  
  17. Install or connect the following:

    Timing belt
     
    No. 2 Timing belt guide
     
    Right-hand engine mounting bracket
     
    Timing belt covers Nos. 1 and 2
     
    Crankshaft pulley. Tighten to 162 ft. lbs. (220 Nm).
     
    Right-hand engine mounting stay No. 2
     
    Engine moving control rod
     
    Air cleaner bracket
     
    Brake master cylinder reservoir and bracket
     
    Valve covers
     
    Ignition coil
     
    Radiator intake hose
     
    Air intake surge tank
     
    Emission control valve hoses
     
    Air intake assembly
     
    Battery and battery tray
     
    Wiper motor and link assembly
     
    Top cowl ventilator louver assembly
     
    Wiper and blade assembly
     
    Right-hand front fender apron seal
     
    Engine splash shields
     
    Right-hand front wheel
     
    Engine covers
     
    Negative battery cable
     

  18.  
  19. Refill the cooling system to the correct level.
  20.  
  21. Refill the engine oil to the correct level.
  22.  
  23. Start the engine and check for leaks.
  24.  
  25. If necessary, perform the initialization procedure, as outlined in the Chassis Electrical System.
  26.  

 
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