Repair Procedure: Disassembly

Disassemble the engine to remove the timing cover and replace the RH and LH camshaft housing sub-assemblies.

1. Remove the engine assembly.

Refer to the Technical Information System (TIS), 2007 model year ES 350 Repair Manual, Engine/Hybrid System - Engine Mechanical - 2GR-FE Engine Mechanical: Engine Assembly: Removal.





2. Remove the No. 1 oil pipe.

A. Remove the 2 oil pipe unions and the oil pipe.

B. Remove the oil control valve filter LH and gaskets.





3. Remove the oil pipe.

A. Remove the bolt.

B. Remove the 2 oil pipe unions and the oil pipe.

C. Remove the oil control valve filter RH and gaskets.

4. Remove the oil filter element.





A. Remove the drain plug.

NOTE

Do NOT remove the O-ring from the oil filter cap.





B. Connect the hose to the pipe.

C. Insert the pipe with the hose into the oil filter cap.

D. Make sure that the oil is completely drained and remove the pipe and O-ring.





E. Using the SST, remove the oil filter cap.

SST P/N: 09228-06501





F. Remove the oil filter element and O-ring from the oil filter cap.

NOTE

Do NOT use any tools when removing the O-ring to prevent the O-ring groove from being damaged.

5. Remove the crankshaft pulley.





A. Using the SST, loosen the crankshaft pulley bolt.

SST P/N: 09213-70011 (09213-70020), 09330-00021





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

SST P/N: 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)





6. Remove the front engine mounting bracket No. 1 LH by removing the 6 bolts.

7. Remove the water inlet housing.





A. Remove the 2 bolts, nut, and water inlet housing.





B. Remove the 2 O-rings.

8. Remove the cylinder head cover sub-assembly (for bank 1).





A. Remove the 12 bolts, seal washer, head cover, and gasket.

B. Remove the 3 gaskets.

9. Remove the cylinder head cover sub-assembly (for bank 2).





A. Remove the 12 bolts, seal washer, head cover, and gasket.

NOTE

The baffle plate is located on the back of the portion shown. Do NOT damage the baffle plate when removing the head cover.





B. Remove the 3 gaskets.

10. Remove the No. 2 oil pan sub-assembly.





A. Remove the 16 bolts and 2 nuts.





B. Insert the blade of the SST between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.

SST P/N: 09032-00100

NOTE

Be careful NOT to damage the contact surfaces of the oil pans.





11. Remove the oil strainer sub-assembly by removing the bolt, 2 nuts, oil strainer, and gasket.

12. Remove the oil pan sub-assembly.





A. Remove the 16 bolts and 2 nuts.

HINT

Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage.





B. Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver.

NOTE

Be careful NOT to damage the contact surfaces of the cylinder block and oil pan.

HINT

Tape the screwdriver tip before use.





C. Remove the 2 O-rings.

D. Using a Torx socket wrench E8, remove the 2 stud bolts:

^ One on the timing cover.

^ One on the lower cylinder block.





13. Remove the water pump assembly by removing the 16 bolts, water pump, and gasket.





14. Remove the timing chain cover sub-assembly.

A. Remove the 15 bolts and 2 nuts as shown.

B. Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a taped screwdriver.

NOTE
Be careful NOT to damage the contact surfaces of the cylinder head, cylinder block, and chain cover.

C. Remove the 4 bolts, chain cover plate, and gasket.





D. Remove the gasket.





15. Using a taped screwdriver, pry out the timing chain case oil seal and remove it.

16. Set the No. 1 cylinder to TDC/compression.

A. Temporarily tighten the pulley set bolt.





B. Set the timing mark on the crank angle sensor plate to the RH block bore center line (TDC/compression).





C. Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown.

If NOT, turn the crankshaft 1 revolution (360°) and align the timing marks as above.

17. Remove the No. 1 chain tensioner assembly.





A. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.

B. Move the stopper plate downward to set the lock, and insert a pin of 1.27 mm (0.05 in.) diameter into the stopper plate's hole.





C. Remove the 2 bolts and chain tensioner.

18. Remove the chain tensioner slipper.

19. Remove the chain sub-assembly.





A. Turn the crankshaft counterclockwise 10 degrees to loosen the chain of the crankshaft timing sprocket.

B. Remove the pulley set bolt.





C. Remove the chain from the crankshaft timing sprocket and place it on the crankshaft.





D. Turn the camshaft timing gear assembly on the RH bank clockwise (approximately 60 degrees) and set it as shown. Be sure to loosen the chain between the banks.

E. Remove the chain.

20. Remove the camshaft timing gears and No. 2 chain (for bank 1).





A. While raising the No. 2 chain tensioner, insert a pin of 1.0 mm (0.039 in.) diameter into the hole to fix the No. 2 chain tensioner.





B. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gear assemblies.

NOTE

Be careful NOT to damage the cylinder head with the wrench.

Do NOT disassemble the camshaft timing gear assemblies.

C. Remove the No. 2 chain.





21. Remove the No. 2 chain tensioner assembly by removing the bolt.

22. Remove the camshaft bearing cap (for bank 1).





A. Check that the camshafts are positioned as shown.





B. Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.





C. Uniformly loosen and remove the 12 bearing cap bolts in the sequence shown in the illustration.

NOTE

Uniformly loosen the bolts while keeping the camshaft level.

D. Remove the 5 bearing caps.

23. Remove the camshaft.

24. Remove the No. 2 camshaft.





25. Remove the camshaft housing sub-assembly RH by prying between the cylinder head and camshaft housing sub-assembly RH with a taped screwdriver.

NOTE

Be careful NOT to damage the contact surfaces of the cylinder head and camshaft housing.

26. Remove the camshaft timing gears and No. 2 chain (for bank 2).





A. While pushing down the No. 3 chain tensioner, insert a pin of 1.0 mm (0.039 in.) diameter into the hole to fix the No. 3 chain tensioner.





B. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gear assemblies.

NOTE

Be careful NOT to damage the cylinder head with the wrench.

Do NOT disassemble the camshaft timing gear assemblies.

C. Remove the No. 2 chain.





27. Remove the No. 3 chain tensioner assembly by removing the bolt.

28. Remove the camshaft bearing cap (for bank 2).





A. Check that the camshafts are positioned as shown.





B. Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.





C. Uniformly loosen and remove the 13 bearing cap bolts in the sequence shown in the illustration.

NOTE

Uniformly loosen the bolts while keeping the camshaft level.

D. Remove the 5 bearing caps.

29. Remove the No. 3 camshaft.

30. Remove the No. 4 camshaft.





31. Remove the camshaft housing sub-assembly LH. Remove the camshaft housing by prying between the cylinder head and camshaft housing with a taped screwdriver.

NOTE

Be careful NOT to damage the contact surfaces of the cylinder head and camshaft housing.