Repair Procedure

1. Confirm the customer complaint.





2. Remove the cylinder head cover.

A. Relocate the engine harness that lies across the top of the cylinder head cover.

B. Remove the ignition coils.

C. Remove the 16 bolts and cylinder head cover.

3. Remove the chain tensioner.

A. Remove the right front wheel.

B. Remove the front fender apron seal RH.

C. Remove the V-ribbed belt for the vane pump.

D. Rotate the crankshaft clockwise and set the No.1 cylinder at +10 from the TDC/compression.





E. After the timing marks are aligned on the VVT gear place paint marks on the chain and both gears.

F. Rotate the crankshaft counterclockwise by 10 and loosen the tension of the chain.

G. Remove the timing chain cover plate.





H. Align the holes of the stopper plate and tensioner and insert a pin into the stopper plate hole to lock the tensioner.

I. Remove the 2 bolts and chain tensioner.





4. Remove the timing chain guide by removing the bolt.

5. Remove the intake side VVT gear.





A. For Camry ONLY:

Remove the 2 bolts and the No.2 timing chain cover (Figure 5).





B. Remove the service hole plug.





C. Insert the tool through the service hole and remove the bolt of the intake VVT gear while holding the camshaft stationary with a wrench.

^ Be careful NOT to damage the cylinder head or spark plug tube with the wrench.

^ Do NOT disassemble the camshaft timing gear.





D. After the VVT gear is slid in the arrow direction as shown in Figure 8 lower the VVT gear and remove the chain from the VVT gear.

E. Remove the VVT gear from the cam housing.





F. Tie the timing chain to ensure it stays properly aligned with the exhaust and crankshaft timing gear pulleys.

6. Remove the exhaust camshaft assembly with exhaust VVT gear.





A. Remove the 11 bearing cap bolts in the sequence shown in the illustration.





B. Using several steps remove the 10 bearing cap bolts in the sequence shown in the illustration.

C. Remove the 5 bearing caps.

Arrange the removed bearing caps in order to ensure they are installed in their original locations during reassembly.

D. Remove the exhaust camshaft assembly with camshaft timing exhaust gear.

E. Place additional ties on the timing chain to ensure it stays properly aligned with the crankshaft timing gear pulley.

F. Place the exhaust camshaft with camshaft timing exhaust gear in a vise.

Cover the vise with tape and only apply pressure to one of the hexagonal portions of the camshaft.

G. Remove the bolt and camshaft timing exhaust gear assembly.

H. Inspect the camshaft timing exhaust gear assembly.





Is there a section separated from the gear as shown in Figure 12?

^ YES - Go to "Additional Repair Procedure: Pad A" in this TSB for removal of the oil pan and if necessary the timing cover assembly to remove the separated piece(s) and perform additional repairs.

^ NO - Go to step 7.

7. Install the new camshaft timing exhaust gear assembly.





A. Align and attach the knock pin of the No.2 camshaft with the pin hole of the camshaft timing exhaust gear.





B. Check that there is no clearance between the camshaft timing exhaust gear and camshaft flange.

C. With the exhaust camshaft still secured in the vise install the bolt.

Torque: 85 N*m (867 kgf*cm, 63 ft*lbf)

D. Clean the camshaft journals camshaft housing and bearing caps.

E. Apply a light coat of engine oil to the camshaft journal camshaft housing and bearing caps.

F. Install the exhaust camshaft with new camshaft timing exhaust gear assembly installed.

8. Install the camshaft bearing cap.





A. Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.





B. Using several steps uniformly tighten the 10 bolts in the sequence shown in the illustration.

Torque: 27 N*m (275 kgf*cm, 20 ft*lbf)





C. Install the 11 bolts in the order shown in the illustration.

Torque: 16 N*m (163 kgf*cm, 12 ft*lbf)

NOTICE

Make sure that the camshaft rotates smoothly after installing the bearing caps.

9. Install the intake side VVT gear.

A. Confirm the gear is in the unlocked position prior to installation.

NOTICE

The camshaft timing gear MUST be in the unlocked position when installing on the camshaft to prevent damage to the lock pin during tightening. Please see step 9D for instructions to unlock the camshaft timing gear.

B. Remove any remaining ties from the timing chain.





C. Insert the tool from the service hole and install the bolt of the intake VVT gear.

Make sure NOT to lock the camshaft timing gear. If the camshaft timing gear is locked, release the lock according to the following procedure (step 9D).

D. Inspect the camshaft timing gear lock.

If the camshaft timing gear is locked release the lock according to the following procedure.





(1) After cleaning and degreasing the intake side VVT oil hole on the No.1 camshaft bearing cap completely seal the oil hole with adhesive tape or equivalent as shown to prevent air from leaking.

NOTICE
Be sure to seal the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

(2) Make a hole in the adhesive tape covering the oil hole as shown in Figure 20.





(3) Apply approximately 200 kPa (2.0 kgf/sq.cm 29 psi) of air pressure to the hole made in the preceding step then forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

CAUTION
Cover the oil passages with a piece of cloth when applying pressure to keep oil from splashing.

^ If air leaks out, reattach the adhesive tape.

^ Do NOT allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

^ The camshaft timing gear assembly may be turned in the advance direction without applying any force.

^ If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.

(4) Remove the adhesive tape on the VVT hole.

E. Tighten the bolt of the intake VVT gear.

Torque: 85 N*m (867 kgf*cm, 63 ft*lbf)

F. Lock the gear by rotating the camshaft timing gear assembly clockwise.





10. Install the service hole plug with a new gasket.

Torque: 30 N*m (306 kgf*cm, 22 ft*lbf)





11. For Camry ONLY:

Install the No. 2 timing chain cover with the 2 bolts.

Torque: 10 N*m (102 kgf*cm, 7 ft*lbf)





12. Install the timing chain guide with the bolt.

Torque: 21 N*m (214 kgf*cm, 15 ft*lbf)





13. Install the chain to the VVT gear.

NOTICE:
Align the marks that were placed on the gears and chain.

14. Install the chain tensioner.





A. Install the chain tensioner to the service hole.

Torque: 10 N*m (102 kgf*cm, 7 ft*lbf)

B. When installing the tensioner pull out the pin and release the tensioner.

C. Install the timing chain cover plate.

Install a new gasket and the timing chain cover plate with the 4 bolts.

Torque: 10 N*m (102 kgf*cm, 7 ft*lbf)

15. Install the cylinder head cover sub-assembly.

A. Apply a light coat of engine oil to 3 new gaskets.





B. Install the 3 gaskets to the camshaft bearing caps.

C. Install a new gasket to the cylinder head cover.

NOTICE:

Remove any oil from the contact surface.





D. Apply seal packing as shown. Seal Packing: Toyota Genuine Seal Packing Black, Three Bond 1207B, or equivalent Standard Seal Diameter: 3.0 to 6.0 mm (0.118 to 0.236 in.)

Application Width A: 5.0 mm (0.197 in.)

NOTICE

^ Remove any oil from the contact surface.

^ Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

E. Align the cylinder head cover with pin A. Then align the cylinder head cover with pin B and install the cylinder head cover.





F. Install the 16 bolts and then tighten the bolts in the order shown in Figure 29.

Torque: 12 N*m (122 kg~cm, 9 ft*lbf)

NOTICE

Do NOT fill the engine with oil or start and run the vehicle for at LEAST 4 hours after the installation.

G. Confirm proper engine and coolant levels prior to starting the engine and test driving the vehicle.

H. Clear DTCs with Techstream.

16. Confirm the repair.