Toyota Tacoma 2002-06

Camshaft, Bearings & Lifters 2

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Removal & Installation



2TR-FE Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. On vehicles equipped with 4WD, remove the engine undercover subassembly.
  6.  
  7. Drain the engine coolant. Remove the radiator support to frame seal, left side. Remove the fan shroud.
  8.  
  9. Remove the air cleaner cap subassembly. Remove the intake air connector.
  10.  
  11. Disconnect the ignition coil connectors. Disconnect the throttle body motor connector. Disconnect the VSV connector.
  12.  
  13. Disconnect the camshaft position sensor connector. Disconnect the engine wire harness clamps. Remove the ignition coils. Disconnect the PCV hose.
  14.  
  15. Remove the cylinder head cover retaining bolts. Remove the cylinder head cover.
  16.  
  17. Remove the two timing chain guide bolts. Remove the timing chain guide. Remove the O-ring.
  18.  
  19. Position the number one cylinder at TDC on the compression stroke.
    NOTE
    Turn the crankshaft pulley clockwise to align the timing mark notch with the timing mark -0-. Paint marks on the timing chain plates that align with the timing marks on the camshaft timing gear.



    Click image to see an enlarged view

    Fig. Camshaft positioning-2.7L (2TR-FE) engine

  20.  
  21. Hold the hexagonal lobe of the number two camshaft, with a suitable tool. Loosen the bolt. Remove the head straight screw plug. Insert a suitable tool into the service hole of the chain tensioner to hold the stopper plate of the chain tensioner lifted up.
    NOTE
    Lifting up the stopper plate of the chain tensioner unlocks the plunger.

  22.  
  23. While keeping the stopper plate of the chain tensioner lifted up, slightly rotate the hexagonal lobe of the number two camshaft clockwise so that the plunger of the chain tensioner is pushed. Be careful not to damage the camshaft oil delivery pipe.
    NOTE
    With the wrench still installed, remove the suitable tool with the plunger still pushed in. Do not remove the wrench. Removing the suitable tool lifts down the stopper plate and locks the plunger.

  24.  
  25. Insert a 0.118 inch diameter bar into the hole of the stopper plate with the stopper plate of the chain tensioner lifter down and locked. Secure the bar with tape.
    NOTE
    If the bar cannot be installed, rotate the number two camshaft slightly to the left and right. Then insert the bar.

  26.  
  27. Remove the camshaft timing gear bolt. Remove the gear.
  28.  
  29. Using several steps, uniformly loosen and remove the camshaft bearing cap bolts in the proper sequence. Remove the camshaft oil delivery pipe and O-ring. Remove the camshaft bearing cap number one and eight camshaft bearing caps number two. Remove the number one camshaft and the number two camshaft.

    Click image to see an enlarged view

    Fig. Camshaft bearing cap bolt removal sequence-2.7L (2TR-FE) engine

  30.  
  31. Tie the timing chain with a piece of wire.
  32.  
  33. Clamp the camshaft in a soft jaw vise, be sure that the camshaft timing gear does not rotate. Do not clamp the camshaft too tightly in the vise.

    Click image to see an enlarged view

    Fig. Camshaft timing gear removal-2.7L (2TR-FE) engine

  34.  
  35. Cover the four oil path holes of the cam journal with vinyl tape.
    NOTE
    One of the two grooves on the cam journal is for retarding cam timing (upper) the other is for advancing cam timing (lower). Each groove has two oil paths. Plug one of the two paths for each groove with a piece of rubber before wrapping the cam journal with the tape.

  36.  
  37. Puncture the tape covering the advance side path and the retard side path on the opposite side.
  38.  
  39. Apply about 29 psi air pressure into the two paths, from the two punctures. When applying air pressure, cover the paths with a shop rag to prevent oil splashes.
  40.  
  41. Confirm that the camshaft timing gear revolves in the advance direction, when reducing the air pressure on the retard side.
    NOTE
    The lock pin is released and the camshaft timing groove revolves in the advance direction.

  42.  
  43. When the camshaft timing gear reaches the most advanced position, release the air pressure on the retard side path, then release the air pressure on the advance side path.
    NOTE
    If the air pressure on the advance path is released first, the camshaft timing gear assembly occasionally shifts in the retard direction abruptly. This may damage the lock pin. Be sure to release the air pressure on the retard side first.

  44.  
  45. Remove the fringe bolt of the camshaft timing gear.
    NOTE
    Do not remove the other three bolts.

  46.  

To install:

  1. Clean all surfaces.
  2.  
  3. Put the camshaft timing gear and the camshaft together by aligning the key groove and the straight pin.
  4.  
  5. Gently press the gear against the camshaft and turn the gear. Push further at the position where the pin fits the groove.
    NOTE
    Be sure not to turn the camshaft timing gear to the retard angle side (to the right angle).

  6.  
  7. Check that there is no clearance between the gear-s fringe and the camshaft. Tighten the fringe bolt to 58 ft. lbs.
  8.  
  9. Check that the camshaft timing gear can move to the retard side (the right angle) and is locked in the extreme retard position.
  10.  
  11. Check that the valve rocker arm is correctly installed. Apply clean engine oil to the camshaft-s cam portion and the cylinder head journals.
  12.  
  13. Install the chain onto the camshaft timing gear, with the painted mark of the link aligned with the timing mark of the camshaft timing gear.

    Click image to see an enlarged view

    Fig. Valve rocker arm installation-2.7L (2TR-FE) engine



    Click image to see an enlarged view

    Fig. Camshaft positioning-2.7L (2TR-FE) engine

  14.  
  15. Position the two camshafts in there mounting on the engine, see illustration.
    NOTE
    Align the paint mark with the timing mark before installing the camshaft.

  16.  
  17. Provisionally install the number one camshaft bearing cap. Check the proper location of each of the number two camshaft bearing caps and install them.
  18.  
  19. Install a new O-ring onto the number one camshaft bearing cap. Provisionally install the camshaft oil delivery pipe.
  20.  
  21. Tighten the camshaft bearing cap bolts to specification and in the proper sequence.
    NOTE
    Bolt -A- is tightened to 9 ft. lbs. All other bolts are tightened to 11 ft. lbs.



    Click image to see an enlarged view

    Fig. Camshaft bearing cap location, identification and torque sequence-2.7L (2TR-FE) engine

  22.  
  23. Check that each timing mark is set as indicated in the illustration.

    Click image to see an enlarged view

    Fig. Camshaft timing mark alignment-2.7L (2TR-FE) engine

  24.  
  25. Install the timing chain onto the camshaft timing gear, with the paint mark aligned with the timing mark on the camshaft timing gear.
  26.  
  27. Align the number two camshaft straight pin and timing gear straight pin hole. Install the camshaft timing gear onto the number two camshaft.
    NOTE
    If the straight pin and straight pin hole are difficult to align, slightly rotate the number two camshaft to the left and right, then attempt to align them.

  28.  
  29. Hold the hexagonal lobe of the number two camshaft with a wrench. Tighten the bolt to 58 ft. lbs.
  30.  
  31. Remove the 0.118 inch diameter bar from the chain tensioner. Apply adhesive, part number 08833-00070 or equivalent, to two or three threads of the timing gear case with head straight screw plug. Install the timing gear case with head straight screw plug and tighten to 12 ft. lbs.
  32.  
  33. Install a new O-ring onto the camshaft bearing cap. Install the two timing chain guide bolts. Tighten to 7 ft. lbs.
  34.  
  35. Apply seal packing, part number 08826-00080 or equivalent, to the cylinder head as indicated in the illustration. Provisionally install the cylinder head cover bolts and nuts. Tighten bolts -A- to 80 inch lbs. Tighten bolts -B- to 80 inch lbs. Retighten bolts -A- to 80 inch lbs.
    NOTE
    Be sure to remove any oil from the contact surfaces of the cylinder head cover and the cylinder head. Install the cover within three minutes after applying the seal packing. Do not add engine oil for at least two hours after installing the cover.



    Click image to see an enlarged view

    Fig. Cylinder head cover bolt sealant application and bolt identification-2.7L (2TR-FE) engine

  36.  
  37. Continue the installation in the reverse order of the removal procedure.
  38.  
  39. Be sure to fill the engine with the proper grade and type engine coolant.
  40.  
  41. Be sure to fill the engine with the proper grade and type engine oil.
  42.  
  43. Start the engine and check for leaks. Correct as required.
  44.  

3RZ-FE Engine


Click image to see an enlarged view

Fig. Camshafts and related components-2.7L (3RZ-FE/M) 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:

    Air cleaner cap
     
    Mass Air Flow (MAF) meter and the resonator
     
    Accelerator cable from the throttle body, if equipped with a manual transmission
     
    Accelerator and throttle cables from the throttle body, if equipped with an automatic transmission
     
    Cruise control cable from the actuator, if equipped with cruise control
     
    Intake air connector
     
    Air hose for Idle Air Control (IAC)
     
    Vacuum sensing hose
     
    Wire clamp for the engine wiring harness
     
    Positive Crankcase Ventilation (PCV) hoses
     
    Spark plug wires from the spark plugs
     
    Engine wiring harness clamps and harness
     
    Air conditioning compressor connector, if equipped with air conditioning
     
    Oil pressure sensor connector
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Engine coolant temperature sender gauge connector
     
    Exhaust Gas Recirculation (EGR) gas temperature sensor connector
     
    Vacuum Switching Valve (VSV) connector for the EGR
     
    2 vacuum hoses from the VSV for the EGR
     
    Ground strap from the cowl top panel
     
    Engine wiring harness from the air intake chamber
     
    Throttle Position (TP) sensor connector
     
    IAC valve connector
     
    Crankshaft Position (CKP) sensor connector
     
    Knock (KS) sensor connector
     
    Data Link Connector 1 (DLC1) from the bracket
     
    Engine wiring harness clamp
     
    EGR pipe
     
    Intake chamber stay
     
    Air intake chamber assembly.
     
    Evaporative Emission (EVAP) hose from the throttle body
     
    Brake booster vacuum hose from the union
     
    Water bypass hose from the water bypass pipe
     
    Water bypass hose from the cylinder head rear cover
     
    Front engine hanger
     
    Engine wiring harness brackets
     
    Cylinder head cover
     

  8.  
  9. Set No. 1 cylinder to Top Dead Center (TDC) compression stroke. The groove on the crankshaft pulley should align with the 0 mark on the timing chain cover and the timing marks (1 and 2 dots) of the camshaft gears should form a straight line in respect to the cylinder head surface. If not, turn the crankshaft 1 revolution (360 degrees).

    Click image to see an enlarged view

    Fig. Camshafts TDC/compression timing marks. Marks with 1 and 2 dots will be in straight line on cylinder head surface-2.7L (3RZ-FE/M) engine



    Click image to see an enlarged view

    Fig. Secure the exhaust camshaft sub-gear to the main gear with a service bolt-2.7L (3RZ-FE/M) engine



    Click image to see an enlarged view

    Fig. Exhaust camshaft bearing cap bolt removal sequence-2.7L (3RZ-FE/M) engine



    Click image to see an enlarged view

    Fig. Intake camshaft bearing cap bolt removal sequence-2.7L (3RZ-FE/M) engine



    Click image to see an enlarged view

    Fig. Engage both camshaft gears while matching the timing marks-2.7L (3RZ-FE/M) engine

  10.  
  11. Remove the chain tensioner and gasket.
  12.  
  13. Remove the camshaft timing gear as follows:
    1. Remove the 2 semi-circular plugs.
    2.  
    3. Place matchmarks on the camshaft timing gear and No. 1 timing chain.
    4.  
    5. Hold the hexagon head portion of the exhaust camshaft with a wrench and remove the fastener and distributor gear.
    6.  
    7. Hold the hexagon head portion of the intake camshaft with a wrench and remove the bolt.
    8.  
    9. Remove the camshaft timing gear and chain from the intake camshaft and leave on the slipper and damper.

      Click image to see an enlarged view

      Fig. Using a wrench to hold the camshaft-2.7L (3RZ-FE/M) engine

    10.  

  14.  
  15. Remove exhaust camshafts:
    1. Bring the service bolt hole of the driven sub-gear upward by turning the hexagon head portion of the exhaust camshaft with a wrench.
    2.  
    3. Secure the exhaust camshaft sub-gear to the driven gear with a service bolt (6mm diameter, 0.63-0.79 inches in length and 1.0mm in thread pitch).
      NOTE
      When removing the camshaft, be sure that the torsional spring force of the sub-gear has been eliminated by the above operation.

    4.  
    5. Uniformly loosen and remove the bearing cap bolts in several passes, in the sequence shown.
    6.  
    7. Remove the bearing caps and camshaft. Make a note of the bearing cap positions for proper installation.
    8.  

  16.  
  17. Remove or disconnect the following:
    NOTE
    If the camshaft is not being lifted out straight and level, reinstall the No. 3 bearing cap with the 2 bolts. Then, alternately loosen and remove the 2 bearing cap bolts with the camshaft gear pulled up.



    Intake camshaft bearing cap bolts in several passes, in the sequence shown
     
    Bearing caps and camshaft. Make a note of the bearing cap positions for proper installation.
     



    Valve lifters and shims from the cylinder head. Arrange the valve lifters and shims in correct order.
     

  18.  

To install:

Click image to see an enlarged view

Fig. Intake camshaft bearing cap bolt torque-2.7L (3RZ-FE/M) engine



Click image to see an enlarged view

Fig. Exhaust camshaft bearing cap bolt torque sequence-2.7L (3RZ-FE/M) engine

  1. Install the valve lifters and shims in their proper locations. Check that the valve lifter rotates smoothly by hand.
  2.  
  3. Install the intake camshaft, as follows:
    1. Apply engine oil to the thrust portion of the intake camshaft.
    2.  
    3. Position the intake camshaft with the knock pin facing upward.
    4.  
    5. Install the bearing caps in their proper locations. Apply a light coat of engine oil to the threads and install the cap bolts. Uniformly tighten the cap bolts, in sequence, to 12 ft. lbs. (16 Nm).
    6.  

  4.  
  5. Install the exhaust camshaft, as shown:
    1. Apply engine oil to the thrust portion of the intake camshaft.
    2.  
    3. Engage the exhaust camshaft gear to the intake camshaft gear by matching the timing marks (1 and 2 dots) on each other.
    4.  
    5. Roll down the exhaust camshaft onto the bearing journals while engaging the gears with each other. Install the bearing caps in their proper locations.
    6.  
    7. Apply a light coat of engine oil to the threads and install the cap bolts. Uniformly tighten the cap bolts in the sequence shown to 12 ft. lbs. (16 Nm).
    8.  
    9. Remove the service bolt from the driven sub-gear. Check that the intake and exhaust camshafts turns smoothly.
    10.  

  6.  
  7. Set No. 1 cylinder to Top Dead Center (TDC) of the compression stroke: Crankshaft pulley groove align with 0 mark on timing cover and camshafts timing marks with 1 dot and 2 dots will be straight line on the cylinder head surface.
  8.  
  9. Install the timing gear. Place the gear over the straight pin of the intake camshaft.
    1. Hold the intake camshaft with a wrench. Install and tighten the bolt to 54 ft. lbs. (74 Nm).
    2.  
    3. Hold the exhaust camshaft and install the bolt and distributor gear. Tighten the bolt to 34 ft. lbs. (46 Nm).
    4.  

  10.  
  11. Install or connect the following:

    Chain tensioner, using a new gasket (mark toward the front)
     
    Recheck the engine for proper valve timing. Check and adjust the valve clearance.
     
    Semi-circular plug
     
    Recheck the engine for proper valve timing.
     
    Cylinder head cover with a new gasket
     
    Engine wiring harness brackets
     
    Front engine hanger. Tighten the bolts to 30 ft. lbs. (42 Nm).
     
    Air intake chamber assembly. Tighten the bolts to 15 ft. lbs. (20 Nm).
     
    Hoses
     
    Intake chamber stay
     
    Air intake chamber stay. Tighten the bolts to 15 ft. lbs. (20 Nm).
     
    EGR pipe. Tighten the bolts to 13 ft. lbs. (18 Nm), nut -A- to 14 ft. lbs. (19 Nm) and nut -B- to 15 ft. lbs. (20 Nm).
     
    Engine wiring harness
     
    Spark plug wires to the spark plugs
     
    PCV hoses
     
    Intake air connector. Tighten the bolts to 13 ft. lbs. (18 Nm).
     
    Air hose for the IAC
     
    Vacuum sensing hose
     
    Wire clamp for the engine wiring harness
     
    Cruise control cable to the actuator, if equipped with cruise control
     
    Accelerator cable to the throttle body, if equipped with a manual transmission
     
    Accelerator and throttle cables to the throttle body, if equipped with an automatic transmission
     
    Air cleaner cap, MAF meter and the resonator assembly
     
    Negative battery cable
     

  12.  
  13. Refill the cooling system.
  14.  
  15. Start the engine and check for leaks.
  16.  
  17. Check the ignition timing. Road test the vehicle for proper operation.
  18.  
  19. Recheck all fluid levels.
  20.  

 
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