Removal

2AR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

2. REMOVE FRONT WHEEL RH

3. DISCONNECT FRONT FENDER LINER RH Removal

4. REMOVE REAR ENGINE UNDER COVER RH Removal

5. REMOVE AIR CLEANER CAP SUB-ASSEMBLY Removal

6. REMOVE AIR CLEANER CASE SUB-ASSEMBLY Removal

7. DISCONNECT ENGINE WIRE

(a) Disconnect the connectors and clamps, remove the bolts and nuts and disconnect the engine wire from the engine.





8. REMOVE IGNITION COIL ASSEMBLY Removal

9. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Removal

10. REMOVE CRANKSHAFT POSITION SENSOR Removal

11. SEPARATE RADIATOR RESERVE TANK ASSEMBLY

(a) Remove the 2 bolts and separate the radiator reserve tank assembly.





12. SET NO. 1 CYLINDER TO TDC/COMPRESSION

(a) Turn the crankshaft pulley until its timing notch (groove) and the timing mark "0" of the timing chain cover are aligned.





Text in Illustration





(b) Check that each matchmark of the camshaft timing gear and camshaft timing exhaust gear are aligned with each matchmark 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.

13. REMOVE TIMING CHAIN COVER PLATE

(a) Remove the 4 bolts, timing chain cover plate and gasket.





14. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Turn the crankshaft approximately 10° clockwise.





(b) Turn the crankshaft approximately 10° counterclockwise.





(c) Align the holes of the stopper plate and tensioner, and insert a pin into the stopper plate hole to lock the tensioner.





Text in Illustration





(d) Turn the crankshaft approximately 10° clockwise.





(e) Remove the 2 bolts, chain tensioner and gasket.





NOTICE:
Make sure not to drop the gasket inside the timing chain cover.

(f) Turn the crankshaft approximately 10° counterclockwise.





15. REMOVE TIMING CHAIN GUIDE Removal

16. REMOVE TIMING CHAIN COVER TIGHT PLUG Disassembly

17. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

(a) Hold the hexagonal portion of the camshaft with a wrench and remove the bolt from the camshaft.





NOTICE:
Be careful not to damage the cylinder head or spark plug tube with the wrench.

(b) Separate the camshaft timing gear assembly from the camshaft.





(c) Remove the timing chain from the camshaft timing gear assembly, and turn the camshaft timing gear assembly approximately 180°.





Text in Illustration





(d) Remove the camshaft timing gear assembly.





NOTICE:
Do not disassemble the camshaft timing gear.

18. REMOVE CAMSHAFT BEARING CAP

(a) Using several steps, remove the 11 bearing cap bolts in the sequence shown in the illustration.





(b) Using several steps, remove the 10 bearing cap bolts in the sequence shown in the illustration.





(c) Remove the 5 bearing caps.

HINT
Arrange the removed parts in the correct order.

19. REMOVE CAMSHAFT

(a) Remove the camshaft from the camshaft housing.





20. REMOVE NO. 2 CAMSHAFT

(a) Hold up the chain and remove the No. 2 camshaft from the camshaft housing.





(b) Suspend the chain with a string or equivalent as shown in the illustration.





NOTICE:
Be careful not to drop the chain inside the timing chain cover.

21. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

(a) Remove the flange bolt and camshaft timing exhaust gear assembly.





NOTICE:
Do not disassemble the camshaft timing exhaust gear.

22. REMOVE OIL CONTROL VALVE FILTER Disassembly

23. REMOVE NO. 1 CAMSHAFT BEARING Disassembly

24. REMOVE NO. 2 CAMSHAFT BEARING Disassembly