Lexus ES: Removal

Lexus ES (XZ10) Service Manual / Engine & Hybrid System / 2gr-fks (engine Mechanical) / Camshaft / Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during camshaft removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
Battery terminal is disconnected/reconnected	Perform steering sensor zero point calibration	Lane Control System
		Pre-collision System
		Parking Support Brake System*1
		Lighting System
	Memorize steering angle neutral point	Parking Assist Monitor System
	Memorize steering angle neutral point	Panoramic View Monitor System
	Initialize power trunk lid system	Power Trunk Lid System
Replacement of ECM	Vehicle Identification Number (VIN) registration	MIL comes on
Replacement of ECM	ECU communication ID registration (Immobiliser system)	Engine start function
Replacement of throttle body with motor assembly Cleaning the deposits from the throttle body with motor assembly Replacement of camshaft (for intake or exhaust camshaft) Replacement of camshaft timing gear assembly Replacement of camshaft timing exhaust gear assembly Replacement of fuel injector assembly (for port injection) Replacement of fuel injector assembly (for direct injection) Replacement of fuel pump assembly (for high pressure side) Replacement of ignition coil assembly Air leaks from intake system Gas leak from exhaust system is repaired	Inspection after repair	Poor idle, etc. Engine start function, etc.
Replacement of automatic transaxle assembly	Perform reset memory Input transaxle compensation code into ECM Perform road test to allow ECM to learn	Large shift shock Deterioration of fuel efficiency	for Initialization: for Registration:
Replacement of ECM (If transaxle compensation code read from ECM)	Perform reset memory*2 Transfer transaxle compensation code Perform road test to allow ECM to learn
Replacement of ECM (If transaxle compensation code not read from ECM)	Perform reset memory*2 Reset transaxle compensation code Perform road test to allow ECM to learn
Replacement of ECM	Code registration (Smart access system with push-button start (for Start Function, Gasoline Model)	Wireless Door Lock Control System Smart Access System with Push-button Start (for Entry Function, Gasoline Model) Smart Access System with Push-button Start (for Start Function, Gasoline Model) Steering lock function Telematics System
Replacement of automatic transaxle fluid	ATF thermal degradation estimate reset	The value of the Data List item "ATF Thermal Degradation Estimate" is not estimated correctly
Suspension, tires, etc. (The vehicle height changes because of suspension or tire replacement)	Rear television camera assembly optical axis adjustment (Back camera position setting)	Parking assist monitor system	for Initialization: for Calibration:
	Perform headlight ECU sub-assembly LH initialization	Lighting system
Front wheel alignment adjustment	Perform "Reset Memory". Perform acceleration sensor zero point calibration and store system information memorization.	VSC is disabled or malfunctions DTCs are output Slip indicator light illuminates ABS warning light illuminates
Replacement of front television camera assembly Replacement of front bumper assembly Replacement of radiator grille	Front television camera view adjustment	Panoramic View Monitor System	for Initialization for Calibration
Replacement of front bumper assembly	Measure ultrasonic sensor detection angle Ultrasonic sensor detection angle registration	Parking Support Alert System Parking Support Brake System

*1: When performing learning using the Techstream.
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*2: Not necessary when ECM replaced with new one

NOTICE:

After the engine switch is turned off, the radio receiver assembly records various types of memory and settings. As a result, after turning the engine switch off, make sure to wait at least 85 seconds before disconnecting the cable from the negative (-) battery terminal. (for Audio and Visual System)
After the engine switch is turned off, the radio receiver assembly records various types of memory and settings. As a result, after turning the engine switch off, make sure to wait at least 85 seconds before disconnecting the cable from the negative (-) battery terminal. (for Navigation System)

PROCEDURE

1. INSTALL ENGINE ASSEMBLY TO ENGINE STAND

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2. REMOVE ENGINE HANGERS

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3. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

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4. DISCONNECT VENTILATION HOSE

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5. DISCONNECT PURGE VALVE (PURGE VSV)

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6. REMOVE NO. 2 SURGE TANK STAY

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7. REMOVE INTAKE AIR SURGE TANK ASSEMBLY

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8. REMOVE AIR SURGE TANK TO INTAKE MANIFOLD GASKET

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9. REMOVE IGNITION COIL ASSEMBLY

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10. REMOVE VACUUM PUMP ASSEMBLY

for TMMK Made:
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for TMC Made:
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11. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

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12. REMOVE WIRE HARNESS CLAMP BRACKET

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13. REMOVE WATER FILLER BRACKET

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14. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 1)

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15. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 1)

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16. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 2)

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17. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 2)

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18. REMOVE VVT SENSOR (for Intake Side of Bank 1)

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19. REMOVE VVT SENSOR (for Exhaust Side of Bank 1)

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20. REMOVE VVT SENSOR (for Intake Side of Bank 2)

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21. REMOVE VVT SENSOR (for Exhaust Side of Bank 2)

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22. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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23. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

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24. REMOVE SPARK PLUG TUBE GASKET

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25. REMOVE TIMING CHAIN COVER PLATE

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26. SET NO. 1 CYLINDER TO TDC (COMPRESSION)

(a) Turn the crankshaft clockwise to align the timing mark (cutout) on the crankshaft pulley with the "0" timing mark on the timing chain cover assembly.

*a	Timing Mark (Cutout)
*b	"0" Timing Mark

(b) Check that the timing marks of the camshaft timing gear assemblies are aligned with the timing marks of the camshaft bearing caps as shown in the illustration.

HINT:

If the marks are not aligned, turn the crankshaft again to align the marks.

*A	for Bank 2
*B	for Bank 1
*a	Timing Mark
*b	Paint Mark

(c) Place paint marks on the timing marks and sprockets of each camshaft timing gear assembly and on the links of the chain sub-assembly.

HINT:

Be sure to place the paint marks on 2 links of the chain sub-assembly and on the sprockets of the camshaft timing gear assemblies at the locations of the timing marks of the camshaft timing gear assemblies.

27. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Turn the crankshaft approximately 30° counterclockwise so that there is some slack in the chain sub-assembly.

HINT:

This prevents the valves and pistons from interfering with each other.

(b) Align the hole in the lever of the No. 1 chain tensioner assembly with the hole in the tensioner body as shown in the illustration, and then insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole.

NOTICE:

Check that the pin is locked.

*a	Lever Hole
*b	Tensioner Body
*c	Pin

(c) Turn the crankshaft clockwise to align the timing mark (cutout) on the crankshaft pulley with the "0" timing mark on the timing chain cover assembly.

*a	Timing Mark (Cutout)
*b	"0" Timing Mark

(d) Remove the 2 bolts and No. 1 chain tensioner assembly from the cylinder head sub-assembly.

NOTICE:

Do not drop the No. 1 chain tensioner assembly or bolts into the timing chain cover assembly.

28. DISCONNECT CHAIN SUB-ASSEMBLY (for Bank 1)

(a) Turn the crankshaft clockwise until it is in the position shown in the illustration so that there is some slack in the chain sub-assembly between the banks.

CAUTION:

As the camshafts may turn suddenly, do not touch the camshafts or camshaft timing gears.

HINT:

When turning the crankshaft, engine oil may spray out of the oil holes.

(b) Turn the crankshaft clockwise until it is in the position shown in the illustration so that the chain sub-assembly can be removed easily.

HINT:

When turning the crankshaft, engine oil may spray out of the oil holes.

5 to 10°

(c) Remove the chain sub-assembly from the sprocket of the camshaft timing gear assembly and set it on the camshaft timing gear assembly.

CAUTION:

As the camshaft may turn suddenly and pinch your fingers when the chain sub-assembly is removed, pinch the chain sub-assembly and lift it upward to remove it from the sprocket.

29. SEPARATE NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Remove the bolt to separate the No. 2 chain tensioner assembly from the camshaft housing sub-assembly.

30. REMOVE CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1)

(a) Use a wrench to hold the hexagonal portion of the camshaft and remove the camshaft timing gear bolt from the camshaft timing gear assembly.

*a	Hold
	Turn

NOTICE:

Be careful not to damage the camshaft, camshaft housing sub-assembly or spark plug tube with the wrench.
If the camshaft timing gear bolt has been struck or dropped, replace it.

31. REMOVE CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1)

(a) Use a wrench to hold the hexagonal portion of the No. 2 camshaft and remove the camshaft timing gear bolt from the camshaft timing exhaust gear assembly.

NOTICE:

Be careful not to damage the No. 2 camshaft, camshaft housing sub-assembly or spark plug tube with the wrench.
If the camshaft timing gear bolt has been struck or dropped, replace it.

*a	Hold
	Turn

32. REMOVE CAMSHAFT BEARING CAP (for Bank 1)

(a) Slide the camshaft timing gear assembly and camshaft timing exhaust gear assembly as shown in the illustration.

(b) Remove the bolts and camshaft bearing caps in the order shown in the illustration. Immediately after removing a camshaft bearing cap, install replacement bolts and washers in the order shown in the illustration.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

NOTICE:

Do not install the camshaft bearing caps when installing replacement bolts and washers.
Be sure to follow the numerical order when performing this procedure.
Do not allow replacement bolts or washers to contact the camshaft.
Do not drop replacement bolts or washers into the cylinder head sub-assembly.

HINT:

Arrange the removed parts so that they can be reinstalled in their original locations.
Part number for replacement bolts: 91551-F0850 (9 bolts)
Part number for replacement washers: 90201-12028 (18 washers)

*a	Replacement Bolt and Washer
*b	Part Removal
*c	Replacement Bolt and Washer Installation

33. REMOVE NO. 2 CAMSHAFT

(a) While lifting up the camshaft timing exhaust gear assembly, remove the No. 2 chain tensioner assembly.

(b) Lift up the rear of the No. 2 camshaft so that it is at an angle.

34. REMOVE CAMSHAFT

(a) Lift up the rear of the camshaft so that it is at an angle.

(b) Pull the camshaft as shown in the illustration to remove it from the camshaft timing gear assembly.

35. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY (for Bank 1)

(a) Remove the camshaft timing exhaust gear assembly.

36. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY (for Bank 1)

(a) Remove the camshaft timing gear assembly and No. 2 chain sub-assembly.

NOTICE:

Do not drop the chain sub-assembly into the gap between the engine and timing chain cover assembly.

(b) Suspend the chain sub-assembly with a string or equivalent.

37. DISCONNECT CHAIN SUB-ASSEMBLY (for Bank 2)

(a) Turn the crankshaft counterclockwise to align the timing mark (cutout) on the crankshaft pulley with the "0" timing mark on the timing chain cover assembly.

*a	Timing Mark (Cutout)
*b	"0" Timing Mark

(b) Remove the chain sub-assembly from the sprocket of the camshaft timing gear assembly and set it on the camshaft timing gear assembly.

CAUTION:

As the camshaft may turn suddenly and pinch your fingers when the chain sub-assembly is removed, pinch the chain sub-assembly and lift it upward to remove it from the sprocket.

38. SEPARATE NO. 3 CHAIN TENSIONER ASSEMBLY

(a) Remove the bolt to separate the No. 3 chain tensioner assembly from the camshaft housing sub-assembly LH.

39. REMOVE CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2)

(a) Use a wrench to hold the hexagonal portion of the No. 3 camshaft sub-assembly and remove the camshaft timing gear bolt from the camshaft timing gear assembly.

*a	Hold
	Turn

NOTICE:

Be careful not to damage the No. 3 camshaft sub-assembly, camshaft housing sub-assembly LH or spark plug tube with the wrench.
If the camshaft timing gear bolt has been struck or dropped, replace it.

40. REMOVE CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2)

(a) Use a wrench to hold the hexagonal portion of the No. 4 camshaft sub-assembly and remove the camshaft timing gear bolt from the camshaft timing exhaust gear assembly.

*a	Hold
	Turn

NOTICE:

Be careful not to damage the No. 4 camshaft sub-assembly, camshaft housing sub-assembly LH or spark plug tube with the wrench.
If the camshaft timing gear bolt has been struck or dropped, replace it.

41. REMOVE CAMSHAFT BEARING CAP (for Bank 2)

(a) Slide the camshaft timing gear assembly and camshaft timing exhaust gear assembly as shown in the illustration.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

NOTICE:

Do not install the camshaft bearing caps when installing replacement bolts and washers.
Be sure to follow the numerical order when performing this procedure.
Do not allow replacement bolts or washers to contact the camshaft.
Do not drop replacement bolts or washers into the cylinder head LH.

HINT:

Arrange the removed parts so that they can be reinstalled in their original locations.
Part number for replacement bolts: 91551-F0850 (8 bolts)
Part number for replacement washers: 90201-12028 (16 washers)

*a	Replacement Bolt and Washer
*b	Part Removal
*c	Replacement Bolt and Washer Installation

42. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY

(a) While lifting up the camshaft timing exhaust gear assembly, remove the No. 3 chain tensioner assembly.

(b) Lift up the rear of the No. 4 camshaft sub-assembly so that it is at an angle.

(c) Pull the No. 4 camshaft sub-assembly as shown in the illustration to remove it from the camshaft timing exhaust gear assembly.

43. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY

(a) Lift up the rear of the No. 3 camshaft sub-assembly so that it is at an angle.

(b) Pull the No. 3 camshaft sub-assembly as shown in the illustration to remove it from the camshaft timing gear assembly.

44. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY (for Bank 2)

(a) Remove the camshaft timing exhaust gear assembly.

45. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY (for Bank 2)

(a) Remove the camshaft timing gear assembly and No. 2 chain sub-assembly.

NOTICE:

Do not drop the chain sub-assembly into the gap between the engine and timing chain cover assembly.

(b) Suspend the chain sub-assembly with a string or equivalent.

SEE MORE:

Precaution

PRECAUTION BASIC REPAIR HINT (a) HINTS ON OPERATIONS 1 Attire Always wear a clean uniform. A hat and safety shoes must be worn. 2 Vehicle protection Prepare a grille cover, fender cover, seat cove

Inspection

INSPECTION PROCEDURE 1. INSPECT BRAKE VACUUM CHECK VALVE ASSEMBLY (a) Check that there is ventilation from the booster side to the engine side, and no ventilation from the engine side to the booster side of the brake vacuum check valve assembly. HINT: If the result is not as specified, replace th

Lexus ES: Removal

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Installation

Cylinder Block

Precaution

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Precaution

Inspection