Removal and Installation Unit Egine Toyota Camry 2012-2017

Illustration:

Removal:

REMOVE ENGINE HANGERS
Remove the 2 bolts and 2 engine hangers.

REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

REMOVE MANIFOLD STAY
REMOVE NO. 2 MANIFOLD STAY
REMOVE EGR INLET EXHAUST MANIFOLD PLATE (for PZEV)
REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (except PZEV)
REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET

REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY

REMOVE WATER BY-PASS HOSE

REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)
DISCONNECT NO. 2 VENTILATION HOSE
REMOVE UNION TO CONNECTOR TUBE HOSE
REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
REMOVE INTAKE MANIFOLD

REMOVE SENSOR WIRE

REMOVE KNOCK CONTROL SENSOR
REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
REMOVE ENGINE COOLANT TEMPERATURE SENSOR
REMOVE IGNITION COIL ASSEMBLY

DISASSEMBLY

REMOVE ENGINE COVER JOINT

REMOVE SPARK PLUG
REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
REMOVE CAMSHAFT POSITION SENSOR
REMOVE OIL FILLER CAP SUB-ASSEMBLY
REMOVE CRANKSHAFT POSITION SENSOR
REMOVE VENTILATION VALVE SUB-ASSEMBLY

REMOVE VENTILATION CASE SUB-ASSEMBLY

Remove the 8 bolts and 2 nuts.

Remove the ventilation case by prying between the ventilation case and cylinder block with a screwdriver.

REMOVE SEPARATOR CASE

Remove the 2 bolts, separator case and gasket.

REMOVE NO. 1 WATER BY-PASS PIPE

Remove the bolt, 2 nuts, water by-pass pipe and gasket.

REMOVE WATER INLET
REMOVE THERMOSTAT

REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
Remove the bolt and V-ribbed belt tensioner.

REMOVE ENGINE WATER PUMP ASSEMBLY

REMOVE WATER INLET HOUSING

Remove the 4 bolts, nut, inlet water housing and gasket.

REMOVE CRANKSHAFT PULLEY

Using SST, hold the crankshaft pulley and loosen the pulley bolt. Further loosen the bolt until 2 or 3 threads are screwed into the crankshaft.

Using SST and the pulley bolt, remove the crankshaft pulley.

REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

Remove the 16 bolts, 3 seal washers, cylinder head cover and gasket.

Remove the 3 gaskets from the camshaft bearing caps.

REMOVE SPARK PLUG TUBE GASKET

Using a screwdriver, pry out the 4 plug tube gaskets.

REMOVE ENGINE MOUNTING BRACKET RH
REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

REMOVE TIMING CHAIN COVER TIGHT PLUG

Using a 14 mm hexagon wrench, remove the plug and gasket.

REMOVE TIMING CHAIN COVER PLATE
Remove the 4 bolts, timing chain cover plate and gasket.

REMOVE TIMING CHAIN COVER OIL SEAL
SET NO. 1 CYLINDER TO TDC/COMPRESSION
REMOVE TIMING CHAIN GUIDE
REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY
REMOVE CHAIN TENSIONER SLIPPER
REMOVE CHAIN SUB-ASSEMBLY
REMOVE NO. 1 CHAIN VIBRATION DAMPER

REMOVE CRANKSHAFT TIMING SPROCKET

Remove the crankshaft timing sprocket from the crankshaft.

REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY
REMOVE CAMSHAFT BEARING CAP

REMOVE OIL CONTROL VALVE FILTER
Remove the oil control valve filter from the No. 1 camshaft bearing cap.

REMOVE CAMSHAFT
REMOVE NO. 1 CAMSHAFT BEARING
Remove the No. 1 camshaft bearing.

REMOVE NO. 2 CAMSHAFT BEARING
Remove the No. 2 camshaft bearing.

REMOVE CAMSHAFT HOUSING STUD BOLT
REMOVE CAMSHAFT BEARING CAP SETTING RING PIN
REMOVE CAMSHAFT HOUSING STRAIGHT PIN
REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
REMOVE VALVE LASH ADJUSTER ASSEMBLY
REMOVE VALVE STEM CAP
REMOVE CYLINDER HEAD SUB-ASSEMBLY
REMOVE CYLINDER HEAD GASKET

REMOVE CYLINDER BLOCK WATER JACKET SPACER
Remove the cylinder block water jacket spacer from the cylinder block.

REMOVE OIL FILTER CAP ASSEMBLY

REMOVE OIL PAN SUB-ASSEMBLY

Remove the 11 bolts and 2 nuts.

Insert the blade of an oil pan seal cutter between the oil pan and stiffening crankcase, cut off the applied sealer and remove the oil pan.

REMOVE OIL STRAINER SUB-ASSEMBLY
Remove the 3 bolts, oil strainer and gasket.

REMOVE NO. 1 OIL PAN BAFFLE PLATE
Remove the 5 bolts and oil pan baffle plate.

INSPECT CRANKSHAFT BACKLASH
Using a dial indicator, measure the backlash of the crankshaft and balance shaft as shown in the illustration.

Standard backlash

0.005 to 0.020 mm (0.000197 to 0.000787 in.)

Maximum backlash

0.020 mm (0.000787 in.)

REMOVE ENGINE BALANCER ASSEMBLY
Remove the 7 bolts and engine balancer.

INSPECT BALANCE SHAFT THRUST CLEARANCE

REMOVE STIFFENING CRANKCASE ASSEMBLY
Remove the 7 bolts.

Using a screwdriver, remove the stiffening crankcase by prying between the stiffening crankcase and cylinder block at the places shown in the illustration.

REMOVE STIFFENING CRANKCASE STUD BOLT
REMOVE STIFFENING CRANKCASE RING PIN

REMOVE REAR ENGINE OIL SEAL
Remove the rear engine oil seal from the cylinder block.

INSPECTION

INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
Turn the roller by hand to check that it turns smoothly.

If the roller does not turn smoothly, replace the valve rocker arm sub-assembly.

INSPECT VALVE LASH ADJUSTER ASSEMBLY

Keep the adjuster free from dirt and foreign matter.Use only clean engine oil

Place the lash adjuster into a container full of new engine oil.
Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger.
Squeeze SST and the lash adjuster together to move the plunger up and down 5 to 6 times.
Check the movement of the plunger and bleed the air.
After bleeding the air, remove SST. Then try to quickly and firmly press the plunger with your fingers.

INSPECT CAMSHAFT OIL CLEARANCE
INSPECT CAMSHAFT THRUST CLEARANCE

INSPECT CAMSHAFT
Inspect the camshaft runout.

Place the camshaft on V-blocks.
Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout, 0.03 mm (0.00118 in.) If the circle runout is more than the maximum, replace the camshaft sub-assembly.

Inspect the cam lobes:

Item	Specified Condition
Intake	44.163 to 44.305 mm (1.739 to 1.744 in.)
Exhaust	44.144 to 44.286 mm (1.738 to 1.744 in.)

Item	Specified Condition
Intake	44.013mm (1.733 in.)
Exhaust	43.996mm (1.732 in.)

Inspect the camshaft journals:

Item	Specified Condition
No. 1 journal	34.449 to 34.465 mm (1.356 to 1.357 in.)
Other journals	22.959 to 22.975 mm (0.904 to 0.905 in)

INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear.

Check that there is no clearance between the camshaft timing gear and camshaft flange:

Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear by hand.
Check the lock of the camshaft timing gear.
Release the lock pin.

Clean the camshaft journal with non-residue solvent.
Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.
Open a hole at port A shown in the illustration.
While applying approximately 200 kPa (2.0 kgf/ cm2 , 29 psi) of air pressure to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

Check for smooth rotation:
Turn the camshaft timing gear within its movable range (26.5 to 28.5°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly.

Remove the vinyl tape and rubber pieces from the camshaft.

Remove the bolt and camshaft timing gear.

INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
Align and attach the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear.

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

Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing exhaust gear by hand.

Check the lock of the camshaft timing exhaust gear.
Make sure that the camshaft timing exhaust gear is locked.

Release the lock pin.

Clean the camshaft journal with non-residue solvent.
Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.
Prick a hole in the tape placed on the advance side path. Prick a hole in the tape placed on the retard side path, on the opposite side to that of the advance side path, as shown in the illustration.
Apply approximately 200 kPa (2.0 kgf/cm2 , 29 psi) of air pressure to the two open paths (the advance side path and retard side path).

Check that the camshaft timing exhaust gear turns in the retard direction when reducing the air pressure applied to the advance side path.

When the camshaft timing exhaust gear moves to the most retarded position, release the air pressure from the advance side path, and then release the air pressure from the retard side path.

Check for smooth rotation.
Turn the camshaft timing exhaust gear within its movable range (21.5 to 23.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear turns smoothly.

Check the lock at the most advanced position. Make sure that the camshaft timing exhaust gear locks at the most advanced position.

Remove the vinyl tape and rubber pieces from the camshaft.

Remove the bolt and camshaft timing gear.

INSPECT CHAIN SUB-ASSEMBLY

Using a spring scale, pull the chain with a force of 147 N (15 kgf, 33.0 lbf) as shown in the illustration.Using a vernier caliper, measure the length of 15 pins.

Maximum chain elongation

137.7 mm (5.42 in.)

INSPECT CRANKSHAFT TIMING SPROCKET

Place the chain around the sprocket.

Using a vernier caliper, measure the sprocket diameter with the chain. Minimum sprocket diameter (with chain) 59.94 mm (2.36 in.), If the diameter is less than the minimum, replace the chain and crankshaft timing sprocket.

INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY
Move the stopper plate counterclockwise to release the lock. Push the plunger and check that it moves smoothly.

INSPECT CHAIN TENSIONER SLIPPER
Measure the worn depth of the chain tensioner slipper.

Maximum depth 1.0 mm (0.0394 in.) If the depth is more than the maximum, replace the chain tensioner slipper.

INSPECT NO. 1 CHAIN VIBRATION DAMPER
Measure the worn depth of the chain vibration damper.

Maximum depth 1.0 mm (0.0394 in.) If the depth is more than the maximum, replace the No. 1 chain vibration damper.

INSPECT TIMING CHAIN GUIDE
Measure the worn depth of the timing chain guide.

Maximum depth 1.0 mm (0.0394 in.) If the depth is more than the maximum, replace the timing chain guide.

INSPECT NO. 1 BALANCE SHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while moving the No. 1 balance shaft back and forth.

Standard thrust clearance 0.05 to 0.09 mm (0.00197 to 0.00354 in.) Maximum thrust clearance 0.09 mm (0.00354 in.) If the thrust clearance is more than the maximum, replace the engine balancer assembly.

INSPECT NO. 2 BALANCE SHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while moving the No. 2 balance shaft back and forth.

INSPECT BALANCE SHAFT BACKLASH

Secure the No. 2 balance shaft in place, and then using a dial indicator, measure the backlash of the No. 1 and No. 2 balance shafts as shown in the illustration.

Standard backlash

0.04 to 0.17 mm (0.00157 to 0.00669 in.)

Maximum backlash

0.17 m (0.00669 in.)

INSPECT CYLINDER HEAD BOLT
Using a vernier caliper, measure the diameter of the threads at the measurement point.

REASSEMBLY

INSTALL ENGINE BALANCER ASSEMBLY
Check that the alignment marks of the balance shaft damper cover and balance shaft driven gear are aligned.

Place a wrench on the rear cutout part of the No. 2 balance shaft and secure the shaft in place.

Rotate the balance shaft driven gear of the No. 1 balance shaft counterclockwise to align the alignment mark of the balance shaft driven gear with the alignment mark of the balance shaft damper cover.

Install the engine balancer to the stiffening crankcase with the 3 bolts, and tighten the bolts in the sequence shown in the illustration.

Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf)

INSTALL STIFFENING CRANKCASE STUD BOLT
Using an E5 and E8 “TORX” socket wrench, install the stud bolts.

Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) for stud bolt B Torque: 9.5 N*m (97 kgf*cm, 84 in.*lbf).

INSTALL STIFFENING CRANKCASE RING PIN

Using a plastic-faced hammer, tap in 2 new ring pins until they stop.

4.3 to 5.3 mm (0.169 to 0.209 in.)

INSTALL STIFFENING CRANKCASE ASSEMBLY
Rotate the crankshaft clockwise so that the crankshaft key is at the position 90° from the bottom as shown in the illustration.

Apply seal packing in a continuous line as shown in the illustration.

Check that the rear cutout parts are as shown in the illustration.

Clean the bolts and their installation holes
Apply adhesive to 3 or more threads of the ends of bolts A.

Temporarily install the stiffening crankcase with the 11 bolts.

Item	Length
Bolt A	65 mm (2.56 in.)
Bolt B	35 mm (1.38 in.)
Bolt C	125 mm (4.92 in.)
Bolt D	165 mm (6.50 in.)

Tighten the 11 bolts in the sequence shown in the illustration to install the stiffening crankcase

for Bolt A

Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) except Bolt A

Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf).

INSTALL NO. 1 OIL PAN BAFFLE PLATE
Install the oil pan baffle plate and uniformly tighten the 5 bolts in several steps, in the sequence shown in the illustration.

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

INSTALL OIL STRAINER SUB-ASSEMBLY
Apply a light coat of engine oil to a new gasket.
Align the protrusion of the gasket with the cutout of the oil strainer, and install the gasket to the oil strainer.

Install the oil strainer with the 3 bolts in several steps, in the sequence shown in the illustration.
Torque: 9 N*m (92 kgf*cm, 80 in.*lbf)

INSTALL OIL PAN SUB-ASSEMBLY
Apply seal packing in a continuous line as shown in the illustration.

Install the oil pan with the 11 bolts and 2 nuts in several steps, in the sequence shown in the illustration.

INSTALL OIL FILTER CAP ASSEMBLY
INSTALL REAR ENGINE OIL SEAL

INSTALL CYLINDER BLOCK WATER JACKET SPACER
Install the water jacket spacer to the cylinder block.

INSTALL CYLINDER HEAD GASKET
INSTALL CYLINDER HEAD SUB-ASSEMBLY
SET CAMSHAFT TIMING GEAR ASSEMBLY

INSTALL CAMSHAFT BEARING CAP SETTING RING PIN
Using a plastic-faced hammer, tap in 10 new ring pins to the camshaft housing.

2.7 to 3.3 mm (0.106 to 0.130 in.)

INSTALL CAMSHAFT HOUSING STRAIGHT PIN
Using a plastic-faced hammer, tap in 2 new straight pins to the camshaft housing.

5.0 to 7.0 mm (0.197 to 0.276 in.)

INSTALL CAMSHAFT HOUSING STUD BOLT
Using an E8 “TORX” socket wrench, install the stud bolt.

Torque: 9.5 N*m (97 kgf*cm, 84 in.*lbf)

INSTALL NO. 1 CAMSHAFT BEARING
Clean the No. 1 camshaft bearing.

Install the camshaft bearing to the No. 1 camshaft bearing cap.
1. Using a vernier caliper, measure the distance between the camshaft bearing cap edge and the camshaft bearing edge.

Standard dimension A – B or B – A 0 to 0.7 mm (0 to 0.0276 in.)

INSTALL NO. 2 CAMSHAFT BEARING
Clean the No. 2 camshaft bearing.
Install the camshaft bearing to the camshaft housing.
Using a vernier caliper, measure the distance between the camshaft housing edge and the camshaft bearing edge.

1.15 to 1.85 mm (0.0453 to 0.0728 in.)

INSTALL OIL CONTROL VALVE FILTER

Install the oil control valve filter to the No. 1 camshaft bearing cap.

INSTALL CAMSHAFT
INSTALL CAMSHAFT BEARING CAP
INSTALL VALVE STEM CAP
INSTALL VALVE LASH ADJUSTER ASSEMBLY
INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY
INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

INSTALL CRANKSHAFT TIMING SPROCKET
Install the crankshaft timing sprocket to the crankshaft.

ADD ENGINE OIL
SET NO. 1 CYLINDER TO TDC/COMPRESSION
INSTALL NO. 1 CHAIN VIBRATION DAMPER
INSTALL CHAIN SUB-ASSEMBLY
INSTALL CHAIN TENSIONER SLIPPER
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
INSTALL TIMING CHAIN GUIDE
CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

INSTALL 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)

INSTALL TIMING CHAIN COVER TIGHT PLUG
Using a 14 mm hexagon wrench, install a new gasket and the plug.

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

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
INSTALL ENGINE MOUNTING BRACKET RH
INSTALL TIMING CHAIN COVER OIL SEAL

INSTALL SPARK PLUG TUBE GASKET
Install 4 new plug tube gaskets to the cylinder head cover.

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
Apply a light coat of engine oil to 3 new gaskets.

Install the 3 gaskets to the camshaft bearing caps.
Install a new gasket to the cylinder head cover.
Apply seal packing as shown in the illustration.

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.)

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

Install 3 new seal washers and the 16 bolts, and then tighten the bolts in the order shown in the illustration.

Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)

INSTALL CRANKSHAFT PULLEY
Align the pulley set key with the key groove of the crankshaft pulley.

Torque: 260 N*m (2651 kgf*cm, 192 ft.*lbf)

INSTALL CRANKSHAFT POSITION SENSOR

INSTALL WATER INLET HOUSING
Install a new gasket and the inlet water housing with the 4 bolts and nut.

Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)

INSTALL ENGINE WATER PUMP ASSEMBLY

INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
Install the V-ribbed belt tensioner with the bolt.

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