Removal
2ZR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL
REMOVAL
1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
HINT: Removal.
2. INSTALL ENGINE STAND Removal
3. REMOVE INTAKE MANIFOLD Removal
4. REMOVE FUEL TUBE SUB-ASSEMBLY Removal
5. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY Removal
6. REMOVE FUEL INJECTOR ASSEMBLY Removal
7. REMOVE IGNITION COIL ASSEMBLY Removal
8. REMOVE OIL LEVEL DIPSTICK SUB-ASSEMBLY Removal
9. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Removal
10. REMOVE MANIFOLD STAY Removal
11. REMOVE EXHAUST MANIFOLD Removal
12. REMOVE VENTILATION HOSE Removal
13. DISCONNECT NO. 3 WATER BY-PASS HOSE Removal
14. REMOVE NO. 1 WATER BY-PASS PIPE Removal
15. REMOVE WATER BY-PASS HOSE Removal
16. REMOVE INLET WATER HOSE Removal
17. REMOVE INLET WATER Removal
18. REMOVE THERMOSTAT Removal
19. REMOVE RADIO SETTING CONDENSER Removal
20. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Disassembly
21. SET NO. 1 CYLINDER TO TDC/COMPRESSION Removal
22. REMOVE CRANKSHAFT PULLEY Removal
23. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY Disassembly
24. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY Removal
25. REMOVE TIMING CHAIN COVER OIL SEAL Disassembly
26. REMOVE CHAIN TENSIONER SLIPPER Removal
27. REMOVE NO. 1 CHAIN VIBRATION DAMPER Removal
28. REMOVE CHAIN SUB-ASSEMBLY Removal
29. REMOVE NO. 2 CHAIN VIBRATION DAMPER Removal
30. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
(a) Inspect the lock of the camshaft timing gear.
(b) After cleaning and degreasing the VVT oil hole on the intake side of 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.
(c) Prick a hole in the tape covering the oil hole as shown in the illustration. (Procedure A)
(d) Apply approximately 150 kPa (1.5 kgf/cm2, 22 psi) of air pressure to the hole pricked 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.
(e) Forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).
HINT: Depending on the air pressure applied, the camshaft timing gear assembly may turn in the advance direction without assistance by hand.
(f) Turn the camshaft timing gear assembly within its movable range (26.5 to 28.5°) 2 or 3 times without turning it to the most retarded position. Make sure that the camshaft timing gear assembly turns smoothly.
(g) Remove the adhesive tape from the No. 1 camshaft bearing cap.
31. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
(a) Check the lock of the camshaft timing exhaust gear.
(b) After cleaning and degreasing the VVT oil hole on the exhaust side of 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.
(c) Prick a hole in the tape covering the oil hole as shown in the illustration. (Procedure B)
(d) Apply approximately 200 kPa (2.0 kgf/cm2, 28 psi) of air pressure to the hole pricked 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.
(e) Using a screwdriver with its tip wrapped with tape, 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 using a screwdriver. If the gear is released, it will return to the most advanced position automatically due to force from the spring.
- Do not damage the camshaft timing exhaust gear.
(f) Using a screwdriver with its tip wrapped with tape, turn the camshaft timing exhaust gear within its movable range (19 to 21°) 2 or 3 times without turning it to the most advanced position. Make sure that the camshaft timing exhaust gear turns smoothly.
(g) Remove the adhesive tape from the No. 1 camshaft bearing cap.
32. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
(a) Remove the flange bolt while holding the hexagonal portion of the camshaft, then remove the camshaft timing gear assembly.
NOTICE:
- Before removing the camshaft timing gear, make sure that the lock pin has been released.
- Be sure not to remove the other 4 bolts.
- Keep the camshaft timing gear assembly horizontal while removing it from the camshaft.
33. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
(a) Remove the flange bolt while holding the hexagonal portion of the camshaft, then remove the camshaft timing exhaust gear assembly.
NOTICE:
- Be sure not to remove the other 4 bolts.
- Keep the camshaft timing exhaust gear assembly horizontal while removing it from the camshaft.
34. REMOVE CAMSHAFT BEARING CAP
(a) Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
(b) Uniformly loosen and remove the 15 bearing cap bolts in the sequence shown in the illustration.
NOTE: Uniformly loosen the bolts while keeping the camshaft level.
(c) Remove the 5 bearing caps.
HINT: Arrange the removed parts in the correct order.
35. REMOVE CAMSHAFT
(a) Remove the camshaft.
36. REMOVE NO. 2 CAMSHAFT
(a) Remove the No. 2 camshaft.
37. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Disassembly
38. REMOVE VALVE LASH ADJUSTER ASSEMBLY Disassembly
39. REMOVE NO. 1 CAMSHAFT BEARING
(a) Remove the 2 No. 1 camshaft bearings.
40. REMOVE NO. 2 CAMSHAFT BEARING
(a) Remove the 2 No. 2 camshaft bearings.
41. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY
(a) Remove the 2 bolts.
(b) Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.
NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.
HINT: Tape the screwdriver tip before use.
42. INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Engine Unit
43. INSPECT VALVE LASH ADJUSTER ASSEMBLY Engine Unit