Camshaft Gear/Sprocket: Service and Repair
1. Disable airbag system as described under MAINTENANCE PROCEDURE/AIRBAG SYSTEM DISARMING.
2. Drain coolant.
3. Disconnect accelerator cable and throttle cable, if equipped, from throttle body.
4. Remove cruise actuator and vacuum pump. Refer to ENGINE.
5. Remove air cleaner hose.
6. Remove engine righthand undercover.
7. On ES 250 models, remove suspension lower crossmember.
8. On all models, remove front exhaust pipe.
9. Remove alternator, ISC valve and throttle body.
10. Remove EGR pipe, then the EGR valve and vacuum modulator.
11. Remove vacuum pipe.
12. Remove distributor.
13. Remove exhaust crossover pipe.
14. Disconnect cold start injector connector. Remove cold start injector tube.
Fig. 10 Intake Manifold Removal:
15. Remove air intake chamber as follows:
a. Disconnect PCV, vacuum sensing, fuel pressure, air conditioner control valve, and EGR temperature sensor hoses.
b. Remove intake chamber stays.
c. Remove intake chamber and gaskets.
16. Remove delivery pipes and injectors, Fig. 10.
17. Remove water outlet.
18. Disconnect injector time switch, water temperature sensor, and heater by-pass hose. Remove water bypass outlet.
19. Remove cylinder head rear plate.
20. Remove idler pulley bracket stay, then the intake manifold.
21. Remove righthand exhaust manifold.
22. Remove lefthand exhaust manifold.
23. Remove spark plugs.
24. Remove timing belt, camshaft timing pulleys and No. 2 idler pulley. Refer to TIMING BELT.
25. Remove No. 3 timing belt cover.
26. Remove cylinder head covers, then the spark plug tube gaskets.
REMOVE CAMSHAFTS:
NOTICE: Since the thrust clearance of the camshaft is small. the camshaft must be held level while it is being removed. If the camshaft is not level. the portion of the cylinder head receiving the shaft thrust may crack or be damaged. causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
Remove exhaust camshaft of RH cylinder head
(a) Align the timing marks (two pointed marks) of the camshaft drive and driven gears by turning the camshaft with a wrench.
(b) Secure the exhaust camshaft sub-gear to the driven gear with a service bolt.
Recommended service bolt:
Thread diameter 6 mm
Thread pitch 1.0 mm ;
Bolt length 16 - 20 mm (0.63- 0.79 in.)
HINT: When removing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by the above operation.
(c) Uniformly loosen and remove the eight bearing cap bolts in several passes in the sequence shown.
(d) Remove the four bearing caps and exhaust camshaft.
Fig. 2 RH Cylinder Head Intake Camshaft Bearing Cap Bolt Loosening Sequence:
Remove intake camshaft of RH cylinder head
(a) Uniformly loosen and remove the ten bearing cap bolts in several passes in the sequence shown.
(b) Remove the five bearing caps, oil seal and intake camshaft.
Remove exhaust camshaft of LH cylinder head
(a) Align the timing marks (one pointed mark) of the camshaft drive and driven gears by turning the camshaft with a wrench.
(b) Secure the exhaust camshaft sub-gear to the driven gear with a service bolt.
Recommended service bolt:
Thread diameter 6 mm
Thread pitch 1.0 mm
Bolt length 16 - 20 mm (0.63- 0.79 in.)'
HINT: When removing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by the above operation.
(c) Uniformly loosen and remove the eight bearing cap bolts in several passes in the sequence shown.
(d) Remove the four bearing caps and exhaust camshaft.
Fig. 4 LH Cylinder Head Intake Camshaft Bearing Cap Bolt Loosening Sequence:
Remove intake camshaft of LH cylinder head
(a) Uniformly loosen and remove the ten bearing cap bolts in several passes in the sequence shown.
(b) Remove the five bearing caps, oil seal and intake camshaft.
Fig. 4 LH Cylinder Head Intake Camshaft Bearing Cap Bolt Loosening Sequence:
INSTALL CAMSHAFTS:
NOTICE: Since the thrust clearance of the camshaft is small. the camshaft must be held level while it is being installed. If the camshaft is not level. the portion of the cylinder head receiving the shaft thrust may crack or be damaged. causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
Fig. 15 Intake Cam Installation:
Fig. 9 Bearing Caps To RH Cylinder Head Intake Camshaft Installation:
Install intake camshaft of RH cylinder head
(a) Apply MP grease to the thrust portion of the camshaft.
(b) Place the intake camshaft at 9O°angle of timing mark (two pointed marks) on the cylinder head.
(c) Apply seal packing to the No.1 bearing cap as shown.
(d) Install the five bearing caps in their proper locations.
(e) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
(f) Install and uniformly tighten the eight bearing cap bolts in several passes in the sequence shown.
Fig. 11 Camshaft Drive & Driven Gears Timing Mark Alignment:
Fig. 12 Bearing Caps To RH Cylinder Head Exhaust Camshaft Installation:
Install exhaust camshaft of RH cylinder head
(a) Apply MP grease to the thrust portion of the camshaft.
(b) Align the timing marks (two pointed marks) of the camshaft drive and driven gear.
(c) Place the exhaust camshaft on the cylinder head.
(d) Install the four bearing caps in their proper locations.
(e) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
(f) Install and uniformly tighten the eight bearing cap bolts in several passes in the sequence shown.
Torque: 160 kg-cm (12 ft-lb, 16 Nm)
(g) Remove the service bolt.
Fig. 14 Placing LH Cylinder Head Intake Camshaft At 90 Degrees Of Timing Mark:
Fig. 15 LH Cylinder Head Intake Camshaft Bearing Cap Locations:
Install intake camshaft Of LH cylinder head
(a) Apply MP grease to the thrust portion of the camshaft.
(b) Place the intake camshaft at 90° angle of timing mark (one pointed mark) on the cylinder head.
(c) Apply seal packing to the No.1 bearing cap as shown.
(d) Install the five bearing caps in their proper locations.
(e) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
(f) Install and uniformly tighten the ten bearing cap bolts in several passes in the sequence shown.
Fig. 17 Camshaft Drive & Driven Gear Timing Mark Alignment:
Fig. 18 LH Cylinder Head Exhaust Camshaft Bearing Cap Locations:
Install exhaust camshaft of LH cylinder head
(a) Apply MP grease to the thrust portion of the camshaft.
(b) Align the timing marks (one pointed mark) of the camshaft drive and driven gears.
(c) Place the intake camshaft on the cylinder head.
(d) Install the four bearing caps in their proper locations.
(e) Apply a light coat of engine oil on the threads and under the heads of bearing cap bolts.
(f) Install and uniformly tighten the eight bearing cap bolts in several passes in the sequence shown.
Torque: 180kg-cm (12 ft-lb. 16 Nm)
(g) Remove the service bolt.
Follow cylinder head tightening sequence.
Refer to SPECIFICATIONS/MECHANICAL SPECIFICATIONS/TIGHTENING SPECIFICATIONS for torque values.
Apply seal packing to No. 1 bearing cap, Fig. 16.
Check and adjust valve clearance. Refer to Engine/Cylinder Head Assembly/Valve, Intake/Exhaust/Adjustments.
Install new camshaft seals using seal installer 09223-46011 or equivalent.
Refill coolant.
Adjust timing.
Rearm Airbag System, refer to MAINTENANCE PROCEDURE/AIRBAG SYSTEM DISARMING.