Removal

2ZR-FXE ENGINE MECHANICAL: CAMSHAFT: REMOVAL

1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

Removal

2. INSTALL ENGINE STAND Removal

3. REMOVE ENGINE HANGERS Removal

4. REMOVE THROTTLE BODY ASSEMBLY Removal

5. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE Removal

6. REMOVE EGR PIPE ASSEMBLY Removal

7. REMOVE EGR VALVE ASSEMBLY Removal

8. REMOVE EGR WITH COOLER PIPE SUB-ASSEMBLY Removal

9. REMOVE INTAKE MANIFOLD Removal

10. REMOVE FUEL VAPOR FEED PIPE Removal

11. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY Removal

12. REMOVE NO. 1 DELIVERY PIPE SPACER Removal

13. REMOVE FUEL INJECTOR ASSEMBLY Removal

14. REMOVE IGNITION COIL ASSEMBLY Removal

15. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Disassembly

16. REMOVE CYLINDER HEAD COVER GASKET Disassembly

17. REMOVE SPARK PLUG TUBE GASKET Disassembly

18. SET NO. 1 CYLINDER TO TDC/COMPRESSION

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





Text in Illustration





(b) Check that the timing marks on both the camshaft timing sprocket and the camshaft timing gear are facing upward as shown in the illustration.

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

19. REMOVE CRANKSHAFT PULLEY Removal

20. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Remove the 2 nuts, bracket, chain tensioner and gasket.





NOTICE:
Do not turn the crankshaft without the No. 1 chain tensioner installed.

21. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY Removal

22. REMOVE TIMING CHAIN COVER OIL SEAL Removal

23. REMOVE CHAIN TENSIONER SLIPPER

(a) Remove the chain tensioner slipper from the cylinder block.





24. REMOVE NO. 1 CHAIN VIBRATION DAMPER

(a) Remove the 2 bolts and chain vibration damper.





25. REMOVE NO. 2 CHAIN VIBRATION DAMPER

(a) Remove the 2 bolts and No. 2 chain vibration damper.





26. REMOVE CHAIN SUB-ASSEMBLY

(a) Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear counterclockwise to loosen the chain between the camshaft timing gears.





(b) With the chain loosened, release the chain from the camshaft timing gear and place it on the camshaft timing gear.

HINT
Be sure to release the chain from the sprocket completely.

(c) Turn the camshaft clockwise to return it to the original position and remove the chain.

27. 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.





Text in Illustration





NOTICE:
Be sure to cover 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 in the advance direction (counterclockwise).

HINT
Depending on the air pressure applied, the camshaft timing gear may turn in the advance direction without assistance.

(f) Turn the camshaft timing gear 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 turns smoothly.





(g) Remove the adhesive tape from the No. 1 camshaft bearing cap.

28. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

(a) Remove the flange bolt while holding the hexagonal portion of the camshaft with a wrench, and then remove the camshaft timing gear.





Text in Illustration





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 horizontal while removing it from the camshaft.

29. REMOVE CAMSHAFT TIMING SPROCKET

(a) Remove the flange bolt while holding the hexagonal portion of the camshaft with a wrench, and then remove the camshaft timing sprocket.





30. 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.





NOTICE:
Uniformly loosen the bearing cap bolts while keeping the camshaft housing level.

(c) Remove the 5 bearing caps.

HINT
Arrange the removed parts in the correct order.

31. REMOVE CAMSHAFT

(a) Remove the camshaft.





32. REMOVE NO. 2 CAMSHAFT

(a) Remove the No. 2 camshaft.





33. REMOVE NO. 1 CAMSHAFT BEARING

(a) Remove the 2 No. 1 camshaft bearings.





34. REMOVE NO. 2 CAMSHAFT BEARING

(a) Remove the 2 No. 2 camshaft bearings.





35. 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.





Text in Illustration





NOTICE:
Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

HINT
Tape the screwdriver tip before use.