Removal

2ZR-FE ENGINE MECHANICAL: TIMING GEAR: REMOVAL

REMOVAL

1. REMOVE NO. 2 CYLINDER HEAD COVER Removal
2. DISCONNECT FUEL VAPOR FEED HOSE ASSEMBLY Removal
3. DISCONNECT UNION TO CONNECTOR TUBE HOSE Removal
4. DISCONNECT NO. 2 VENTILATION HOSE
5. SEPARATE WIRE HARNESS





(a) Remove the 2 bolts (*1) and disconnect the 9 connectors and 2 clamps. Then disconnect the wire harness.
(b) Remove the 2 bolts (*2) and disconnect the air tube.
6. REMOVE RADIO SETTING CONDENSER Removal
7. REMOVE IGNITION COIL ASSEMBLY Removal
8. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Disassembly
9. SET NO. 1 CYLINDER TO TDC/COMPRESSION





(a) Turn the crankshaft pulley until its groove and the timing mark "0" of the timing chain cover are aligned.
(b) Check that each timing mark of the camshaft timing gear and sprocket are aligned with each timing mark located as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration.





(c) Place paint marks on the chain in alignment with the timing marks on the camshaft timing gear and camshaft timing exhaust gear.
10. REMOVE NO. 2 CHAIN VIBRATION DAMPER





(a) Using SST, remove the 2 bolts and No. 2 chain vibration damper from the cam cap.
SST: 09961-00950
11. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY Disassembly
12. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY





(a) While holding the hexagonal portion of the No. 2 camshaft with a wrench, loosen the camshaft timing exhaust gear bolt with SST.
SST: 09249-37010
NOTE: Do not remove the other 4 bolts ("TORX" bolt). If any of them is removed, replace the camshaft timing exhaust gear assembly.
HINT: The bolt cannot be removed separately from the camshaft timing exhaust gear assembly due to lack of space.

(b) Hold the hexagonal portion of the intake camshaft with a wrench and turn it slightly counterclockwise to release the chain.





(c) While removing the chain, pull out the camshaft timing exhaust gear assembly horizontally and then upward with the bolts installed.
NOTE: Do not turn the intake camshaft more than necessary.
HINT: Be sure to loosen the chain because the camshaft timing exhaust gear assembly cannot be removed with the chain tensioned.

13. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
(a) Inspect the camshaft timing gear lock.
(1) Check that the camshaft timing gear is locked.
(b) Inspect camshaft timing gear operation.




(1) After cleaning and degreasing the intake side VVT oil hole on the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.
NOTE: Be sure to seal the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.
(2) Make a hole in the adhesive tape covering the oil hole as shown in the illustration. (Procedure A)




(3) Apply approximately 100 kPa (1.0 kgf/cm2, 14.5 psi.) of air pressure to the hole made in procedure A to release the lock pin.

NOTICE:
- If air leaks out, reattach the adhesive tape.
- Cover the oil hole with a piece of cloth when applying air pressure to prevent oil from spraying.
(4) Forcibly turn the camshaft timing gear in the advance direction (counterclockwise).
HINT: Depending on the air pressure applied, the camshaft timing gear may turn in the advance direction without assistance by hand.




(5) Turn the camshaft timing gear within its movable range (27.5°) 2 or 3 times without turning it to the most retarded position. Check that the camshaft timing gear turns smoothly.
(6) Lock the camshaft timing gear.
NOTE: Be sure to turn the camshaft timing gear to the locked position and then confirm that it is securely locked again to prevent the valve timing from being affected.
(7) Remove the adhesive tape from the No. 1 camshaft bearing cap.
14. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
(a) Temporarily install the camshaft timing exhaust gear assembly.




(1) Install the bolt to the camshaft timing exhaust gear assembly.
(2) Align the knock pin on the No. 2 camshaft with the pin hole in the camshaft timing exhaust gear assembly and temporarily install the camshaft timing exhaust gear assembly to the No. 2 camshaft with the bolt.
NOTICE:
- Do not install the chain onto the gear at this step.
- Do not allow the chain to interfere with the gear when installing the gear assembly.

(b) Inspect the camshaft timing exhaust gear lock.
(1) Check that the camshaft timing exhaust gear is locked.
(c) Inspect camshaft timing exhaust gear operation.




(1) After cleaning and degreasing the exhaust side VVT oil hole on the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.
NOTE: Be sure to seal the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.
(2) Make a hole in the adhesive tape covering the oil hole as shown in the illustration. (Procedure B)




(3) Apply approximately 100 kPa (1.0 kgf/cm2, 14.5 psi.) of air pressure to the hole made in procedure B to release the lock pin.

NOTICE:
- If air leaks out, reattach the adhesive tape.
- Cover the oil hole with a piece of cloth when applying air pressure to prevent oil from spraying.
(4) Using a screwdriver with its tip taped, forcibly turn the camshaft timing exhaust gear in the retard direction (clockwise).
NOTICE:
- Be sure to keep the camshaft timing exhaust gear in the retard direction. If the gear is released, it will return to the advanced position automatically due to the force from the spring.
- Do not damage the camshaft timing exhaust gear.




(5) Using a screwdriver with its tip taped, turn the camshaft timing exhaust gear within its movable range (20°) 2 or 3 times without turning it to the most advanced position. Check that the camshaft timing gear turns smoothly.
(6) Lock the camshaft timing exhaust gear.
(7) Remove the adhesive tape from the No. 1 camshaft bearing cap.
(d) Remove the camshaft timing exhaust gear assembly.




(1) Remove the temporarily installed camshaft timing exhaust gear assembly.