Camshaft R&R

Complete removal and replacement of intake and exhaust camshafts on the 2ZR-FE 1.8L engine, including timing chain component service and valve timing adjustment.

Warnings

Tools required

Parts

• Camshaft (intake and/or exhaust as needed) × 2 — Use OEM specification
• Valve cover gasket × 1 — 11213-37010
• Timing cover gasket × 1 — 11391-37020
• Camshaft oil seal (front) × 1 — 90311-38006
• Oil drain plug crush washer × 1 — 90430-12031
• Engine oil 0W-20 × 5 — Use OEM specification
• RTV silicone gasket maker (Toyota FIPG) × 1 — 08826-00080
• Timing chain tensioner (if replacement needed) × 1 — 13540-37010
• VVT-i cam phaser (if replacement needed) × 2 — Use OEM specification
• Threadlocker (medium strength) × 1 — Loctite 243 or equivalent

Fluids

• Toyota Genuine 0W-20 — 4.5 qt
• Toyota Super Long Life Coolant (Pink) — 1 qt

Preparation

1. Ensure engine is completely cold (below 100°F)
2. Disconnect negative battery cable and wait 90 seconds for airbag system discharge
3. Remove engine cover (pull upward to release clips)
4. Drain engine oil completely and install drain plug with new crush washer
5. Remove air intake assembly and air filter housing
6. Disconnect PCV hoses and vacuum lines from valve cover
7. Label and photograph all electrical connectors, vacuum lines, and hose routing
8. Remove ignition coils and spark plugs from all cylinders
9. Position engine support fixture across engine bay or support engine from below with jack and wood block
10. Remove right-side engine mount to allow timing cover access

Procedure

1. 1

   Remove valve cover
   Disconnect VVT solenoid connectors and camshaft position sensor connector. Remove valve cover bolts in reverse of tightening sequence (outside to inside pattern). Carefully lift valve cover off, tapping gently with rubber mallet if stuck. Remove and discard valve cover gasket.
2. 2

   Rotate engine to TDC cylinder #1
   Rotate crankshaft clockwise using 19mm socket on crankshaft pulley bolt until timing marks align: crankshaft pulley groove aligns with '0' mark on timing cover, and both camshaft timing marks (dots or notches) point upward toward 12 o'clock position. Mark this position with paint marker on timing chain and all sprockets.
   ⚠Always rotate engine in clockwise direction only (viewed from front). Never rotate counterclockwise as this can damage timing chain tensioner.
3. 3

   Remove crankshaft pulley and timing cover
   Hold crankshaft pulley with holder tool or use impact wrench to remove crankshaft pulley bolt. Remove crankshaft pulley. Remove all timing cover bolts (note different lengths and locations). Remove timing cover by carefully prying at designated pry points only. Clean all RTV residue from timing cover mating surfaces using plastic scraper.
   Torque spec

   Harmonic Balancer Bolt180 Nm (133 lb-ft)

   Cover Bolts15 Nm (11 lb-ft)
4. 4

   Lock and remove timing chain tensioner
   Verify timing marks are still aligned. Remove timing chain tensioner mounting bolt. Carefully extract tensioner assembly (spring tension will be present). Inspect tensioner for proper operation - plunger should move smoothly and lock when pressed. If installing new tensioner, compress plunger and install retaining pin or clip to keep compressed.
   ⚠Tensioner is spring-loaded. Control removal to prevent sudden release and oil spillage.
   Torque spec

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
5. 5

   Remove timing chain guides
   Remove upper timing chain guide bolts and remove guide. Remove lower timing chain guide if accessible. Inspect guides for wear grooves or damage - replace if groove depth exceeds 1mm or if chain has contacted aluminum backing.
   Torque spec

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

   Remove VVT cam phasers and camshaft sprockets
   Hold intake camshaft stationary using wrench on hexagonal section behind cam phaser. Remove cam phaser bolt (this bolt has threadlocker). Remove intake VVT cam phaser, keeping it upright to prevent oil drainage. Repeat process for exhaust camshaft sprocket. Mark timing chain position on sprockets with paint before removal.
   ⚠Do not allow camshafts to rotate after sprockets are removed. This will alter valve positions.
   Torque spec

   Cam Phaser Bolt65 Nm (48 lb-ft)

   Camshaft Sprocket Bolt80 Nm (59 lb-ft)
7. 7

   Remove camshaft bearing caps
   Mark each camshaft bearing cap with its position number and orientation (intake vs exhaust, cylinder number, direction arrow). Loosen bearing cap bolts in sequence: start from outer caps and work toward center, loosening each bolt 1/4 turn at a time in 3-4 passes to gradually release valve spring pressure. Once all bolts are loose, remove bearing caps and keep in order.
   ⚠️Bearing caps must be loosened gradually in correct sequence. Loosening end caps completely before center caps can bend camshaft or crack bearing caps due to valve spring pressure.
8. 8

   Remove camshafts
   Carefully lift intake camshaft straight up and out of cylinder head. Lift exhaust camshaft straight up and out. Inspect camshaft lobes for scoring, pitting, or wear. Measure lobe height with micrometer if wear is suspected (intake lobe minimum: 42.85mm, exhaust: 42.70mm). Inspect bearing journals for scoring or discoloration.
   ℹ️Camshafts are heavy and awkward. Support full length during removal to prevent dropping.
9. 9

   Inspect cylinder head and prepare for installation
   Inspect camshaft bearing surfaces in cylinder head for scoring or damage. Check valve stem seals for leakage signs. Clean all oil passages with brake cleaner and compressed air. Verify timing chain is still in position on crankshaft sprocket and chain has not skipped. Apply clean engine oil to all camshaft bearing surfaces in cylinder head.
10. 10

    Install new or replacement camshafts
    Liberally coat all camshaft journals and lobes with clean engine oil or assembly lube. Position exhaust camshaft into cylinder head with timing mark facing upward (12 o'clock). Position intake camshaft into cylinder head with timing mark facing upward. Verify both camshaft timing marks point straight up and are parallel to cylinder head surface.
    ⚠Camshafts must be positioned with lobes in correct orientation before bearing caps are installed. Incorrect position will prevent bearing cap installation.
11. 11

    Install camshaft bearing caps
    Apply thin coat of engine oil to bearing cap contact surfaces. Install bearing caps in correct positions following orientation marks made during removal. Install all bearing cap bolts finger-tight. Tighten bearing cap bolts in sequence (center caps first, working outward) in 3 complete passes: 1st pass to 5 Nm, 2nd pass to 10 Nm, 3rd pass to final 14 Nm. Verify camshafts rotate smoothly by hand after installation.
    ⚠Bearing caps must be tightened in correct sequence and multiple passes. Single-pass tightening can bind camshafts or crack bearing caps.
    Torque spec

    Camshaft Bearing Cap Bolts14 Nm (10 lb-ft)
12. 12

    Install VVT cam phasers and timing chain
    Verify crankshaft timing mark is still at TDC. Position timing chain on crankshaft sprocket. Install exhaust camshaft sprocket with timing chain, aligning chain paint marks with sprocket timing mark. Install and hand-tighten sprocket bolt. Install intake VVT cam phaser with timing chain, aligning marks. Apply threadlocker to cam phaser bolt threads. Hold camshaft with wrench on hex and torque cam phaser bolt. Hold exhaust camshaft and torque sprocket bolt.
    ⚠️Timing marks must align exactly. Misalignment of even one chain link will cause engine damage. Verify all three timing marks (crank and both cams) align simultaneously before proceeding.
    Torque spec

    Cam Phaser Bolt65 Nm (48 lb-ft)

    Camshaft Sprocket Bolt80 Nm (59 lb-ft)
13. 13

    Install timing chain guides and tensioner
    Install lower timing chain guide and torque bolts. Install upper timing chain guide and torque bolts. Ensure timing chain tensioner plunger is compressed and locked with pin. Install tensioner and torque bolt. Remove tensioner locking pin to activate tensioner - you should hear/feel it extend against timing chain. Rotate crankshaft 2 complete revolutions clockwise and verify all timing marks realign exactly at TDC.
    ⚠️After rotating engine 2 revolutions, all timing marks must realign perfectly. If marks do not align, timing chain is installed incorrectly. Do not proceed - remove and reinstall chain correctly.
    Torque spec

    Timing Chain Guide Bolts12 Nm (9 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
14. 14

    Install timing cover and crankshaft pulley
    Clean all RTV residue from cylinder block and timing cover mating surfaces. Apply continuous 3mm bead of Toyota FIPG RTV to timing cover groove - bead must be on inboard side of bolt holes. Install timing cover within 3 minutes of RTV application. Install all timing cover bolts and torque in sequence: 8mm bolts first, then 10mm bolts. Install crankshaft pulley, ensuring it seats fully on crankshaft. Torque crankshaft pulley bolt (may require impact wrench).
    ℹ️RTV requires 24 hours to fully cure. Do not add oil or start engine for at least 2 hours after RTV application.
    Torque spec

    Cover Bolts15 Nm (11 lb-ft)

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

    Install valve cover and reassemble
    Install new valve cover gasket in valve cover groove. Clean valve cover mating surface on cylinder head. Position valve cover and install all bolts finger-tight. Torque valve cover bolts in sequence from center outward. Reconnect VVT solenoids and camshaft position sensor. Install spark plugs and ignition coils. Reinstall right-side engine mount and torque mounting bolts. Reconnect all vacuum lines, PCV hoses, and intake assembly.
    Torque spec

    Cover Bolts15 Nm (11 lb-ft)

    Mounting Bolts45 Nm (33 lb-ft)

Reassembly

1. Reinstall engine mount using both mounting bolt torque specifications as applicable (26 Nm and 45 Nm depending on bolt size)
2. Reconnect negative battery cable
3. Fill engine with 4.5 quarts Toyota Genuine 0W-20 engine oil
4. Top off coolant reservoir if any coolant was lost during mount removal
5. Prime oil system by cranking engine for 10 seconds without starting (disable fuel pump or ignition)
6. Check for oil leaks around valve cover, timing cover, and all gasket surfaces before starting engine

Verification

• Start engine and verify oil pressure light extinguishes within 3-5 seconds
• Allow engine to idle and listen for abnormal valve train noise (ticking, knocking, or rattling)
• Check for oil leaks at valve cover gasket, timing cover, and camshaft oil seal
• Verify no check engine light or VVT-related fault codes (P0010, P0011, P0020, P0021)
• Test drive vehicle and verify smooth acceleration with no hesitation or timing-related issues
• Monitor oil pressure gauge (if equipped) during test drive - should read normal range
• Re-check oil level after test drive and top off if needed
• Inspect valve cover and timing cover areas for leaks after 50-100 miles of operation

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