Toyota Prius: Camshaft

• Removal
• Installation

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 Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
Replacement of throttle body assembly Replacement of camshaft (for intake or exhaust camshaft) Replacement of camshaft timing gear assembly Replacement of ignition coil assembly	Inspection After Repair	Poor idle, etc. Engine start function, etc.

CAUTION / NOTICE / HINT

COMPONENTS (REMOVAL)

Procedure		Part Name Code
1	NO. 1 ENGINE UNDER COVER ASSEMBLY	51410	-	-	-
2	DRAIN ENGINE COOLANT (for Engine)	-	-		-

Procedure		Part Name Code
3	WINDSHIELD WIPER MOTOR AND LINK	-	-	-	-
4	WATER GUARD PLATE	55734D	-	-	-
5	OUTER COWL TOP PANEL	55711	-	-	-

Procedure		Part Name Code
6	NO. 2 VENTILATION HOSE	12262	-	-	-
7	IGNITION COIL ASSEMBLY	19500		-	-
8	CAMSHAFT POSITION SENSOR	11101E		-	-
9	ENGINE WIRE	82121	-	-	-
10	NO. 1 FUEL VAPOR FEED HOSE	23826	-	-	-
11	FUEL VAPOR FEED PIPE	23818	-	-	-

●

Non-reusable part

★

Precoated part

Procedure		Part Name Code
12	CYLINDER HEAD COVER SUB-ASSEMBLY	11201		-	-
13	CYLINDER HEAD COVER GASKET	11213	-	-	-
14	SPARK PLUG TUBE GASKET	11193		-	-
15	SET NO. 1 CYLINDER TO TDC (COMPRESSION)	-		-	-
16	NO. 2 CHAIN VIBRATION DAMPER	13562		-	-
17	NO. 1 CHAIN TENSIONER ASSEMBLY	13540		-	-
18	CAMSHAFT TIMING SPROCKET	13523G		-	-
19	INSPECT CAMSHAFT TIMING GEAR ASSEMBLY	13050		-	-
20	CAMSHAFT BEARING CAP	-		-	-
21	NO. 2 CAMSHAFT	13512	-	-	-
22	CAMSHAFT	13511		-	-
23	REMOVE CAMSHAFT TIMING GEAR ASSEMBLY	13050		-	-
24	NO. 1 CAMSHAFT BEARING	-	-	-	-
25	NO. 2 CAMSHAFT BEARING	-	-	-	-

●

Non-reusable part

-

-

PROCEDURE

1. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

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2. DRAIN ENGINE COOLANT (for Engine)

Click here

3. REMOVE WINDSHIELD WIPER MOTOR AND LINK

Click here

4. REMOVE WATER GUARD PLATE

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5. REMOVE OUTER COWL TOP PANEL

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6. DISCONNECT NO. 2 VENTILATION HOSE

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7. REMOVE IGNITION COIL ASSEMBLY

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8. REMOVE CAMSHAFT POSITION SENSOR

Click here

9. DISCONNECT ENGINE WIRE

10. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE

Click here

11. REMOVE FUEL VAPOR FEED PIPE

Click here

12. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

Click here

13. REMOVE CYLINDER HEAD COVER GASKET

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14. REMOVE SPARK PLUG TUBE GASKET

Click here

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

Set the No. 1 cylinder to TDC (Compression) Click here

*a

Paint Mark

*b

Timing Mark

(1) Place paint marks on the chain sub-assembly in alignment with the timing marks on the camshaft timing gear assembly and camshaft timing sprocket.

16. REMOVE NO. 2 CHAIN VIBRATION DAMPER

(1) Using SST, remove the 2 bolts and No. 2 chain vibration damper from the No. 1 camshaft bearing cap.

SST: 09961-00950

17. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

Click here

18. REMOVE CAMSHAFT TIMING SPROCKET

*a	14 mm Union Nut Wrench	*b	Hold
*c	Turn	-	-

(1) While holding the hexagonal portion of the No. 2 camshaft with a wrench, remove the bolt with SST and 14 mm union nut wrench.

SST: 09961-00950

(2) While removing the chain sub-assembly, pull out the camshaft timing sprocket horizontally and then upward.

19. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

Click here

20. REMOVE CAMSHAFT BEARING CAP

(1) Uniformly loosen and remove the 10 bolts in the order shown in the illustration.

NOTICE:

Do not loosen the other bearing cap bolts in this step.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

*a	The removal order of the parts	*b	The installation order of the service bolts and spacers for temporarily tightening the camshaft housing sub-assembly
*c	Service bolt and spacer (Used to temporarily secure the camshaft housing sub-assembly)	-	-

(1) Remove the bolts and camshaft bearing caps in the order shown in the illustration. Immediately after removing each camshaft bearing cap, install service bolts and spacers in the order shown in the illustration.

Torque:

27 N·m {275 kgf·cm, 20 ft·lbf}

21. REMOVE NO. 2 CAMSHAFT

22. REMOVE CAMSHAFT

(1) Hold up the chain sub-assembly and remove the camshaft from the camshaft housing sub-assembly.

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

23. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

*a

Do not remove

-

-

(1) Secure the hexagonal portion of the camshaft in a soft jaw vise.

(2) Remove the bolt and camshaft timing gear assembly.

24. REMOVE NO. 1 CAMSHAFT BEARING

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25. REMOVE NO. 2 CAMSHAFT BEARING

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Installation

INSTALLATION

CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

Procedure		Part Name Code
1	NO. 1 CAMSHAFT BEARING	-		-	-
2	NO. 2 CAMSHAFT BEARING	-		-	-
3	CAMSHAFT TIMING GEAR ASSEMBLY	13050		-	-
4	NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY	13801		-	-
5	CAMSHAFT	13511		-	-
6	NO. 2 CAMSHAFT	13512		-	-
7	CAMSHAFT BEARING CAP	-		-	-
8	CAMSHAFT TIMING SPROCKET	13523G		-	-
9	NO. 1 CHAIN TENSIONER ASSEMBLY	13540		-	-
10	NO. 2 CHAIN VIBRATION DAMPER	13562		-	-
11	SET NO. 1 CYLINDER TO TDC (COMPRESSION)	-		-	-
12	SPARK PLUG TUBE GASKET	11193	-	-	-
13	CYLINDER HEAD COVER GASKET	11213		-	-
14	CYLINDER HEAD COVER SUB-ASSEMBLY	11201		-	-

	N*m (kgf*cm, ft.*lbf): Specified torque	*T1	For use with SST
*T2	For use with SST and a union nut wrench	●	Non-reusable part

Procedure		Part Name Code
15	FUEL VAPOR FEED PIPE	23818	-	-	-
16	NO. 1 FUEL VAPOR FEED HOSE	23826	-	-	-
17	ENGINE WIRE	82121	-	-	-
18	CAMSHAFT POSITION SENSOR	11101E		-	-
19	IGNITION COIL ASSEMBLY	19500		-	-
20	NO. 2 VENTILATION HOSE	12262	-	-	-

	N*m (kgf*cm, ft.*lbf): Specified torque	*	For use with a union nut wrench
●	Non-reusable part	★	Precoated part

Procedure		Part Name Code
21	OUTER COWL TOP PANEL	55711	-	-	-
22	WATER GUARD PLATE	55734D	-	-	-
23	WINDSHIELD WIPER MOTOR AND LINK	-	-	-	-

Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)

N*m (kgf*cm, ft.*lbf): Specified torque

Procedure		Part Name Code
24	ADD ENGINE COOLANT (for Engine)	-	-		-
25	INSPECT FOR COOLANT LEAK (for Engine)	-	-	-
26	NO. 1 ENGINE UNDER COVER ASSEMBLY	51410	-	-	-

N*m (kgf*cm, ft.*lbf): Specified torque

-

-

PROCEDURE

1. INSTALL NO. 1 CAMSHAFT BEARING

Click here

2. INSTALL NO. 2 CAMSHAFT BEARING

Click here

3. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

HINT: Perform "Inspection After Repair" after replacing the camshaft timing gear assembly. Click here

*a

Knock Pin

*b

Knock Pin Hole

(1) Secure the hexagonal portion of the camshaft in a soft jaw vise.

(2) Align and fit the knock pin of the camshaft to the knock pin hole of the camshaft timing gear assembly.

*1	Camshaft Timing Gear Assembly	-	-
*a	Camshaft Flange	*b	No Gap
	Lock	-	-

(1) Check that there is no gap between the camshaft timing gear assembly and camshaft flange.

(2) Tighten the bolt with the camshaft timing gear assembly secured in place.

Torque:

54 N·m {551 kgf·cm, 40 ft·lbf}

NOTICE:

When tightening the bolt, do not allow the camshaft timing gear assembly to rotate.

(3) Check that the camshaft timing gear assembly can move in the retard direction (clockwise) and locks in the most retarded position.

4. SET NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

*1	No. 1 Valve Rocker Arm Sub-assembly	*2	Valve Lash Adjuster Assembly
*3	Valve Stem Cap	-	-
*a	Correct	*b	Incorrect

(1) Make sure that the No. 1 valve rocker arm subassemblies are installed as shown in the illustration.

5. INSTALL CAMSHAFT

HINT: Perform "Inspection After Repair" after replacing the camshaft. Click here

(1) Clean the camshaft journals.

(1) Apply a light coat of engine oil to the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.

*a

Paint Mark

*b

Timing Mark

(1) Hold up the chain sub-assembly, align the timing mark with the paint mark and install the camshaft.

6. INSTALL NO. 2 CAMSHAFT

HINT: Perform "Inspection After Repair" after replacing the No. 2 camshaft. Click here

(1) Clean the No. 2 camshaft journals.

(1) Apply a light coat of engine oil to the No. 2 camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.

(1) Install the No. 2 camshaft to the camshaft housing sub-assembly.

7. INSTALL CAMSHAFT BEARING CAP

*a	Service bolt and spacer (Used to temporarily secure the camshaft housing sub-assembly)	*b	Knock Pin
*c	Paint Mark	*d	Timing Mark
*e	The removal order of the service bolts and spacers for temporarily tightening the camshaft housing sub-assembly	*f	The installation order of the parts

(1) Check the marks and numbers on the camshaft bearing caps, and then remove the service bolts and spacers in the order shown in the illustration. Immediately after removing the service bolts and spacers for each camshaft bearing cap, install the camshaft bearing cap with the bolts in the order shown in the illustration.

Torque:

27 N·m {275 kgf·cm, 20 ft·lbf}

NOTICE:

If the bolts are loosened all at once, seal packing on the camshaft housing sub-assembly and cylinder head sub-assembly may separate, resulting in oil leaks. Therefore, be sure to remove the service bolts and spacers from one camshaft bearing cap at a time.

HINT:

Make sure that the orientation of the straight pin, timing mark and paint mark of the camshaft are as shown in the illustration.

(1) Tighten the 10 bolts in the order shown in the illustration.

Torque:

16 N·m {163 kgf·cm, 12 ft·lbf}

(2) Check the torque of each bolt again.

8. INSTALL CAMSHAFT TIMING SPROCKET

*a

Paint Mark

*b

Timing Mark

(1) Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft slightly counterclockwise to release the chain sub-assembly.

NOTICE:

Do not turn the camshaft more than necessary.

(2) Align the paint mark with the timing mark to install the chain sub-assembly.

*a	14 mm Union Nut Wrench	*b	Torque Wrench Fulcrum Length
*c	Hold	*d	Turn

(1) Using SST, a 14 mm union nut wrench and a wrench, hold the hexagonal portion of the No. 2 camshaft and install the camshaft timing sprocket to the No. 2 camshaft with the bolt.

SST: 09961-00950

Torque:

Specified tightening torque

54 N*m (551 kgf*cm, 40 ft.*lbf)

9. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

Click here

10. INSTALL NO. 2 CHAIN VIBRATION DAMPER

*a

Torque Wrench Fulcrum Length

-

-

(1) Using SST, install the No. 2 chain vibration damper to the No. 1 camshaft bearing cap with the 2 bolts.

SST: 09961-00950

Torque:

Specified tightening torque

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

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

Click here

12. INSTALL SPARK PLUG TUBE GASKET

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13. INSTALL CYLINDER HEAD COVER GASKET

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14. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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15. INSTALL FUEL VAPOR FEED PIPE

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16. CONNECT NO. 1 FUEL VAPOR FEED HOSE

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17. CONNECT ENGINE WIRE

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

18. INSTALL CAMSHAFT POSITION SENSOR

Click here

19. INSTALL IGNITION COIL ASSEMBLY

Click here

20. CONNECT NO. 2 VENTILATION HOSE

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21. INSTALL OUTER COWL TOP PANEL

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22. INSTALL WATER GUARD PLATE

23. INSTALL WINDSHIELD WIPER MOTOR AND LINK

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24. ADD ENGINE COOLANT (for Engine)

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25. INSPECT FOR COOLANT LEAK (for Engine)

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26. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

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