Camshaft R&R

This procedure covers removal and installation of the intake and exhaust camshafts on the 2AR-FE 2.5L engine, including timing chain and VVT components.

Warnings

Tools required

Parts

• Valve cover gasket × 1 — 11213-36010
• Valve cover spark plug tube seals × 4 — Use OEM specification
• Timing cover gasket × 1 — 11329-36010
• Oil pan gasket × 1 — Use OEM specification
• Crankshaft front oil seal × 1 — 90311-38024
• Camshaft oil seals × 2 — Use OEM specification
• VVT-i oil control valve O-ring × 2 — Use OEM specification
• Timing chain tensioner gasket × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — 90430-12031
• Threadlocker (medium strength) × 1 — Use OEM specification
• RTV silicone gasket maker × 1 — Toyota Genuine or equivalent

Fluids

• Toyota Genuine 0W-20 — 5 qt
• Toyota Super Long Life Coolant (Pink) — 2 qt

Preparation

1. Ensure engine is completely cold. Allow at least 2 hours after last operation.
2. Disconnect negative battery cable and secure away from terminal.
3. Remove engine cover if equipped.
4. Drain engine coolant into appropriate container by opening radiator drain and lower hose.
5. Drain engine oil completely and remove oil filter.
6. Remove air intake duct and air cleaner assembly.
7. Disconnect and remove ignition coils and spark plugs.
8. Label and disconnect all electrical connectors on valve cover (VVT solenoids, camshaft position sensors).
9. Remove accessory drive belts.
10. Support engine with jack and block of wood under oil pan if needed for access.
11. Have clean workspace ready for organizing small parts and keeping components in order.

Procedure

1. 1

   Remove valve cover
   Remove valve cover bolts in reverse of tightening sequence (work from outside toward center). Carefully lift valve cover off, tapping gently with rubber mallet if stuck. Inspect valve cover gasket and spark plug tube seals for damage. Clean mating surface thoroughly.
   Torque spec

   Cover Bolts16 Nm (12 lb-ft)
2. 2

   Remove crankshaft pulley and harmonic balancer
   Remove right front wheel and fender liner for access. Use crankshaft pulley holder tool to prevent rotation. Remove crankshaft pulley bolt (turning counterclockwise). Impact wrench is recommended due to high torque. Remove harmonic balancer from crankshaft snout. Mark position of balancer on crankshaft if not keyed.
   ⚠This bolt is extremely tight. Do not use impact wrench without proper pulley holding tool or you may damage crankshaft.
   Torque spec

   Crankshaft Pulley Bolt180 Nm (133 lb-ft)

   Harmonic Balancer Bolt180 Nm (133 lb-ft)
3. 3

   Remove timing chain cover
   Drain any remaining coolant from water pump area. Remove water pump if necessary for access. Remove all timing cover bolts - note there are different sizes (10mm and 8mm heads). Keep track of bolt locations as they vary in length. Carefully separate timing cover from engine block - may require gentle prying with plastic tool. Remove old gasket material from both mating surfaces using plastic scraper. Do not gouge aluminum surfaces.
   ⚠Some timing cover bolts go into water jacket. Note their positions to avoid coolant leaks on reassembly.
   Torque spec

   Cover Bolts16 Nm (12 lb-ft)
4. 4

   Verify and mark timing chain alignment
   Rotate crankshaft clockwise (using socket on crankshaft snout) until No. 1 piston is at TDC on compression stroke. Verify that timing marks on camshaft sprockets align with marks on bearing caps or cylinder head. Verify crankshaft timing mark aligns with mark on block or chain guide. Take multiple clear photos of all timing marks. Use paint pen to mark chain links that align with sprocket timing marks. Count links between marks for reference.
   ⚠️This is the most critical step. Triple-check all timing marks before proceeding. Engine damage will occur if timing is incorrect.
5. 5

   Remove timing chain tensioner and guides
   Remove timing chain tensioner mounting bolt. The tensioner is spring-loaded - control it as you remove it. Remove timing chain guides by removing their mounting bolts. Inspect guides for wear grooves - replace if grooves exceed 1mm depth. Keep all components organized.
   ⚠Tensioner is spring-loaded and may release suddenly. Keep hands clear of moving parts.
   Torque spec

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

   Timing Chain Guide Bolts12 Nm (9 lb-ft)
6. 6

   Remove VVT-i cam phasers and timing chain
   Hold intake camshaft stationary using wrench on hex section (located behind cam phaser). Remove cam phaser bolt. Repeat for exhaust camshaft. Carefully lift both cam phasers together with timing chain. Secure timing chain with wire to prevent it from falling into engine. If chain must be separated from phasers, mark exact position of chain on each phaser sprocket.
   ⚠Do not rotate crankshaft or camshafts once timing chain is removed or timing will be lost.
   Torque spec

   Cam Phaser Bolt65 Nm (48 lb-ft)
7. 7

   Remove camshaft bearing caps
   Loosen camshaft bearing cap bolts in correct sequence - work from outside bolts toward center bolts in multiple passes (3-4 passes, loosening each bolt 1/4 turn per pass). This prevents warping the camshafts or cylinder head. Once all bolts are loose, remove bearing caps in order and keep them organized - they are position-specific and directional. Note arrow marks on caps indicating front of engine. Remove camshafts carefully, keeping intake and exhaust separate.
   ⚠Bearing caps are numbered and directional. Mark them clearly if markings are not visible. Installing caps incorrectly will destroy the camshafts.
   ⚠Never loosen all bolts at once. This will warp the cylinder head and damage camshaft journals.
   Torque spec

   Camshaft Bearing Cap Bolts14 Nm (10 lb-ft)
8. 8

   Inspect and measure camshafts
   Inspect camshaft lobes for scoring, pitting, or excessive wear. Inspect bearing journals for damage or discoloration. Measure camshaft runout using V-blocks and dial indicator - should be less than 0.03mm. Measure cam lobe height - intake minimum is 44.364mm, exhaust minimum is 44.220mm (verify in service manual). Measure journal diameters and compare to specifications. If replacing camshafts, ensure new camshafts match part numbers exactly.
9. 9

   Install camshafts
   Thoroughly clean camshaft journals in cylinder head with clean lint-free cloth. Apply fresh engine oil to all camshaft journals and lobes. Install camshafts in their correct positions (intake and exhaust are different). Ensure camshaft timing gear dowel pins are positioned correctly - approximately 90-120 degrees apart when at TDC No. 1. Apply engine oil to inside of bearing caps. Install bearing caps in correct positions with arrow marks facing front of engine. Install bolts finger-tight initially.
   ⚠Do not mix up intake and exhaust camshafts. They have different profiles and are not interchangeable.
10. 10

    Torque camshaft bearing cap bolts
    Tighten camshaft bearing cap bolts in sequence from center caps working outward. Use 3 passes: first pass to 5 Nm, second pass to 10 Nm, third pass to final specification of 14 Nm. This ensures even loading and prevents warping. Verify camshafts rotate smoothly by hand after torquing - they should rotate with light effort.
    ⚠If camshafts bind or become difficult to rotate, stop immediately. Remove caps and inspect for debris or misalignment.
    Torque spec

    Camshaft Bearing Cap Bolts14 Nm (10 lb-ft)
11. 11

    Install timing chain and VVT-i cam phasers
    Verify crankshaft is still at TDC No. 1. Install timing chain onto crankshaft sprocket. Route chain over idler sprocket if equipped. Install chain onto intake cam phaser, aligning marked chain link with phaser timing mark. Install chain onto exhaust cam phaser with correct marked link alignment. Position both phasers onto camshaft dowel pins simultaneously. Apply medium-strength threadlocker to cam phaser bolts. Hold each camshaft stationary with wrench on hex and torque phaser bolts to specification.
    ⚠️Verify timing marks at least three times before torquing phaser bolts. Incorrect timing will destroy engine on startup.
    Torque spec

    Cam Phaser Bolt65 Nm (48 lb-ft)
12. 12

    Install timing chain guides and tensioner
    Install timing chain guides and torque bolts to specification. Compress timing chain tensioner plunger into body and insert retaining pin or clip to hold compressed. Install tensioner with new gasket and torque bolt. Remove retaining pin - tensioner will apply pressure to chain. Verify chain has proper tension (should have minimal slack but not be over-tight).
    ⚠Ensure tensioner pin/clip is removed after installation or engine will not run properly.
    Torque spec

    Timing Chain Guide Bolts12 Nm (9 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
13. 13

    Verify timing and install timing cover
    Rotate crankshaft two complete revolutions clockwise (viewed from front). Check that all timing marks realign at TDC No. 1. If marks do not align, remove components and start over - timing is incorrect. Once verified, apply thin bead of RTV silicone to timing cover in areas specified in service manual (typically corners where cover meets block). Install new timing cover gasket. Install timing cover and torque bolts in sequence - 8mm bolts first to 25 Nm, then 10mm bolts to 45 Nm. Allow RTV to cure per manufacturer instructions before adding fluids.
    ⚠️If timing marks do not realign after two crankshaft rotations, DO NOT proceed. Disassemble and correct timing.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)
14. 14

    Install crankshaft pulley and harmonic balancer
    Install new crankshaft front oil seal if removed. Ensure crankshaft snout is clean and dry. Install harmonic balancer aligning any marks made during removal. Install crankshaft pulley bolt with light oil on threads. Hold crankshaft pulley with holding tool and torque bolt to 180 Nm. Some bolts are TTY (torque-to-yield) and require additional angle rotation - verify in service manual.
    ℹ️Impact wrench may be required to achieve proper torque. Use proper holding tool to prevent crankshaft rotation.
    Torque spec

    Harmonic Balancer Bolt180 Nm (133 lb-ft)

    Crankshaft Pulley Bolt180 Nm (133 lb-ft)
15. 15

    Install valve cover and accessories
    Install new camshaft position sensors with new O-rings if removed. Torque sensor bolts to specification. Install new VVT-i solenoid O-rings and torque solenoids. Install new spark plug tube seals into valve cover. Apply thin bead of RTV to valve cover at two front corners where timing cover meets cylinder head. Install new valve cover gasket. Install valve cover and torque bolts in sequence from center outward to 10 Nm. Install spark plugs and ignition coils. Reconnect all electrical connectors. Install accessory drive belts. Install air intake system.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)

    Camshaft Position Sensor10 Nm (7 lb-ft)

    VVT Solenoid Bolt10 Nm (7 lb-ft)

Reassembly

1. Install new oil filter and refill engine with 5.0 quarts of Toyota Genuine 0W-20 engine oil.
2. Refill cooling system with Toyota Super Long Life Coolant (Pink) mixed 50/50 with distilled water. Total capacity is approximately 10 quarts but expect to use 2-3 quarts for refilling after this procedure.
3. Install new oil drain plug crush washer and torque drain plug to 35 Nm.
4. Reinstall right front wheel and fender liner.
5. Reconnect negative battery cable.
6. Install engine cover if equipped.

Verification

• Before starting engine, remove all spark plugs and disable fuel system (remove fuel pump fuse). Crank engine for 10-15 seconds while monitoring oil pressure gauge or light. Oil pressure should register within 5 seconds.
• Reinstall spark plugs and fuel pump fuse. Start engine and verify it starts smoothly without abnormal noises (knocking, rattling, or grinding).
• Allow engine to idle and verify no oil or coolant leaks from valve cover, timing cover, or oil pan.
• Monitor for check engine light. If light comes on, scan for codes - P0016, P0017, P0018, or P0019 indicate timing correlation problems.
• Verify VVT-i system operation by monitoring camshaft position sensor data with scan tool during idle and light throttle.
• Test drive vehicle and verify normal acceleration, no hesitation, and no check engine light.
• After 50-100 miles, recheck valve cover and timing cover bolts for proper torque and check for leaks.
• Change engine oil after 500 miles as break-in precaution to remove any metal particles from assembly.

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