Yaris 2007

Camshaft & Lifters

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Removal & Installation



  1. Disconnect the negative battery cable.
  2.  
  3. Remove the ignition coils.
  4.  
  5. Remove the valve cover ventilation hoses.
  6.  
  7. Remove the alternator and drive belt.
  8.  
  9. Remove engine mounting insulator sub-assembly RH. Refer to Engine Assembly.
    NOTE
    When rotating the camshaft with the timing chain removed, rotate the crankshaft damper counterclockwise 40°from the TDC and align its timing notch with the matchmark of the timing chain cover to prevent the pistons from coming into contact with the valves.



    Click image to see an enlarged view

    Fig. Rotate the crankshaft damper counterclockwise 40°from the TDC

  10.  
  11. Follow the illustrations in order. Remove no. 2 camshaft. Set the No. 1 cylinder to TDC / compression:
    NOTE
    If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.


    NOTE
    Loosen the bolts uniformly while keeping the camshaft level.


    NOTE
    Loosen the bolts uniformly while keeping the camshaft level.



    Click image to see an enlarged view

    Fig. Step 1: Turn the crankshaft damper, and align its timing notch with the timing mark "0" of the oil pump



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    Fig. Step2: Check that the timing marks on both the camshaft timing sprocket and the camshaft timing gear are facing upward



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    Fig. Step3: Place paint marks on the chain in the places where the timing marks of the camshaft timing sprocket and the camshaft timing gear are located.



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    Fig. Step 4: Using an 8 mm hexagon wrench, remove the screw plug



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    Fig. Step 5: Insert a screwdriver into the service hole in the chain tensioner to pull the stopper plate of the chain tensioner upward



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    Fig. Step 6: Using a wrench, rotate camshaft No. 2 clockwise to push in the plunger of the chain tensioner



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    Fig. Step 7: Remove the screwdriver from the service hole, then align the hole in the stopper plate with the service hole and insert a 0.12 inch diameter bar into the holes to hold the stopper plate



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    Fig. Step 8: Using a wrench, hold the hexagonal lobe of camshaft No. 2 and remove the flange bolt.



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    Fig. Step 9: Using several steps, loosen and remove the 11 bearing cap bolts uniformly in the sequence then remove camshaft bearing caps No. 1 and No. 2



    Click image to see an enlarged view

    Fig. Step 10: Remove the flange bolt and remove the camshaft timing sprocket



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    Fig. Step11: Remove camshaft No. 2



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    Fig. Step 12: Using several steps, loosen and remove the 8 bearing cap bolts uniformly remove camshaft bearing cap No. 2



    Click image to see an enlarged view

    Fig. Step 13: Hold the chain by hand, and remove the camshaft and the camshaft timing gear assembly



    Click image to see an enlarged view

    Fig. Step 14: Tie the chain with a piece of string as shown

  12.  
  13. Remove the camshaft timing gear assembly:
    1. Clamp the camshaft in a vise and confirm that it is locked.
      NOTE
      One of the 2 grooves located on the cam journal is for retarding cam timing (upper) and the other is for advancing cam timing (lower). Each groove has 2 oil paths. Plug one of the oil paths for each groove with a piece of rubber before wrapping the cam journal with the tape.

    2.  
    3. Cover the 4 oil paths of the cam journal with tape as shown in the illustration.

      Click image to see an enlarged view

      Fig. Cover the 4 oil paths of the cam journal with tape

    4.  
    5. Puncture the tape covering the advance oil path and the retard oil path on the opposite side from the advance oil path.
    6.  
    7. Apply air at about 150 kPa (1.5 kgf*cm2) pressure into the 2 broken paths (the advance side path and the retard side path)
      NOTE
      Cover the paths with a shop rag or piece of cloth to prevent oil splashes.



      Click image to see an enlarged view

      Fig. Apply air pressure into the 2 broken paths

    8.  

  14.  
  15. Confirm that the camshaft timing gear assembly revolves in the timing advance direction when the air pressure on the timing retard path is reduced.
    NOTE
    The lock pin is released, and the camshaft timing gear revolves in the advance direction.

    1. When the camshaft timing gear reaches the most advanced position, release the air pressure on the timing retard side path, and then release the air pressure on the timing advance side path.
      NOTE
      The camshaft timing gear assembly occasionally shifts to the retard side abruptly, if the air pressure on the advance side path is released first. This often results in breakage of the lock pin.

    2.  
    3. Remove the flange bolt and remove the camshaft timing gear assembly.
      NOTE
      Do not remove the other 4 bolts. When reusing the camshaft timing gear, unlock the lock pin inside the camshaft timing gear first.



      Click image to see an enlarged view

      Fig. Exploded view of the camshaft assembly-1 of 2



      Click image to see an enlarged view

      Fig. Exploded view of the camshaft assembly-2 of 2

    4.  

  16.  

To install:

  1. Install camshaft timing gear assembly:
    1. Install the camshaft timing gear assembly onto the camshaft with the lock pin of the camshaft timing gear assembly released.
    2.  
    3. Put the camshaft timing gear assembly and camshaft together with the straight pin of the groove.
    4.  
    5. Turn the camshaft timing gear assembly clockwise while pushing it gently toward the camshaft. When the pin fits the groove, push to ensure a good fit.
      NOTE
      Do not turn the camshaft timing gear in the retard direction (clockwise).

    6.  
    7. Check that there is no clearance between the gear flange and the camshaft.
    8.  
    9. Tighten the flange bolt with the camshaft timing gear fixed. Tighten to 47 ft. lbs. (64 Nm).
      NOTE
      Do not lock the camshaft timing gear assembly when tightening the bolt. Release the lock pin of the camshaft timing gear assembly first, and tighten the bolt when the lock pin is locked in the most retarded position. Tightening the bolts with the lock pin locked could cause breakage of the lock pin.

    10.  
    11. Check that the camshaft timing gear assembly moves smoothly in the retard direction (clockwise) and is locked in the most retarded position.
    12.  

  2.  
  3. Install camshaft:
    1. Apply a light coat of engine oil to the camshaft and camshaft journals.
    2.  
    3. Install the chain onto the camshaft timing gear with the paint mark and the timing mark aligned.
      NOTE
      Tighten each bolt uniformly while keeping the camshaft level.



      Click image to see an enlarged view

      Fig. Install the chain onto the camshaft timing gear with the paint mark and the timing mark aligned

    4.  
    5. Examine the front marks and numbers on camshaft bearing cap No. 2 and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts, in several steps, in the sequence shown in the illustration. Tighten to 9.4 ft. lbs. (13 Nm).

      Click image to see an enlarged view

      Fig. Camshaft bearing cap No. 2 installation sequence

    6.  

  4.  
  5. Install no. 2 camshaft:
    1. Install camshaft No. 2.
    2.  
    3. Hold the chain and align the timing mark on the camshaft timing sprocket with the paint mark of the chain.
    4.  
    5. Align the alignment pin hole in the camshaft timing sprocket with the alignment pin of the camshaft, and install the sprocket onto the camshaft.
    6.  
    7. Provisionally install the flange bolt.
    8.  
    9. Examine the front marks and numbers on camshaft bearing caps No. 1 and No. 2 and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts, in several steps, in the sequence shown in the illustration.
      NOTE
      Tighten each bolt uniformly while keeping the camshaft level.



      Bearing cap no.2: 9.4 ft. lbs. (13 Nm).
       
      Bearing cap no. 1: 17 ft. lbs. (23 Nm).
       

    10.  
    11. Using a wrench, hold the hexagonal lobe of camshaft No. 2 and install the flange bolt. Tighten to 47 ft. lbs. (64 Nm).
    12.  
    13. Remove the bar from the timing chain tensioner.
    14.  
    15. Turn the crankshaft damper and align its timing notch with the timing mark "0" of the oil pump.
    16.  
    17. Check that all the pairs of timing marks are aligned.
    18.  
    19. Apply adhesive to the end 2 or 3 threads of the screw plug. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent
    20.  
    21. Using an 8 mm hexagon wrench, install the screw plug. Tighten to 11 ft. lbs. (15 Nm).
    22.  

  6.  
  7. Inspect the valve clearance:
    1. Turn the crankshaft damper and align its timing notch with the timing mark "0" of the oil pump.
    2.  
    3. Check that both timing marks on the camshaft timing sprocket and camshaft timing gear are facing upward.
      NOTE
      If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

    4.  
    5. Check the valves indicated in the illustration.

      Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
       
      Valve clearance (cold): Intake: 0.006 to 0.010 inches. Exhaust: 0.010 to 0.014 inches
       

    6.  
    7. Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.

      Click image to see an enlarged view

      Fig. Check the valves indicated-First set

    8.  
    9. Turn the crankshaft 1 complete revolution (360°) and align its timing notch with the timing mark "0" of the oil pump.
    10.  
    11. Check the valves indicated in the illustration.

      Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
       
      Valve clearance (cold): Intake: 0.006 to 0.010 inches. Exhaust: 0.010 to 0.014 inches
       

    12.  
    13. Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.

      Click image to see an enlarged view

      Fig. Check the valves indicated-Second set

    14.  

  8.  
  9. To complete installation, reverse the remaining removal procedure.
  10.  
  11. Check for engine oil leaks.
  12.  

 
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