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2ZR-FE Engine Mechanical: Camshaft: Removal

  1. REMOVE FRONT WIPER ARM HEAD CAP  . Refer to REMOVAL .
  2. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH   . Refer to REMOVAL .
  3. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH   . Refer to REMOVAL .
  4. REMOVE HOOD TO COWL TOP SEAL   . Refer to REMOVAL .
  5. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY   . Refer to REMOVAL .
  6. REMOVE COWL TOP VENTILATOR LOUVER LH   . Refer to REMOVAL .
  7. REMOVE FRONT WIPER MOTOR AND LINK  (See REMOVAL )
  8. REMOVE FRONT AIR SHUTTER SEAL RH  . Refer to REMOVAL  .
  9. REMOVE OUTER COWL TOP PANEL  . Refer to REMOVAL  .
  10. REMOVE NO. 2 CYLINDER HEAD COVER  . Refer to REMOVAL .
  11. REMOVE IGNITION COIL ASSEMBLY  . Refer to REMOVAL .
  12. REMOVE RADIO SETTING CONDENSER  . Refer to REMOVAL .
  13. DISCONNECT NO. 2 VENTILATION HOSE 
    1. Disconnect the No. 2 ventilation hose.
    Fig 1: Locating No. 2 Ventilation Hose
    G00514517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. DISCONNECT ENGINE WIRE 
    1. Remove the 2 bolts, 5 connectors, 5 clamps and disconnect the engine wire.
    Fig 2: Identifying Engine Wire
    G00514519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE AIR TUBE ASSEMBLY 
    1. Remove the 2 bolts, 4 hoses and air tube assembly.
    Fig 3: Identifying Air Tube Assembly
    G00514549Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY   . Refer to DISASSEMBLY .
  17. REMOVE CYLINDER HEAD COVER GASKET   . Refer to DISASSEMBLY .
  18. SET NO. 1 CYLINDER TO TDC / COMPRESSION 
    1. Turn the crankshaft pulley until its timing notch (groove) and the timing mark "0" of the timing chain cover are aligned.
      Fig 4: Aligning Matchmarks
      G00514520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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 mark as shown in the illustration.
    3. Place paint marks on the chain in alignment with the timing marks on the camshaft timing gear and camshaft timing exhaust gear.
      Fig 5: Identifying Paint Marks
      G00514521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE SERVICE COVER 
    1. Remove the 5 bolts and service cover.
      Fig 6: Identifying Service Cover Bolts
      G00514522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver with its tip taped, pry at the areas shown in the illustration and remove service cover.
      NOTE: Do not damage the service cover or the contact surfaces of the chain cover.
      Fig 7: Identifying Protective Tape On Screwdriver
      G00514523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE NO. 2 CHAIN VIBRATION DAMPER 
    1. Remove the 2 bolts and No. 2 chain vibration damper from the camshaft bearing cap.
    Fig 8: Locating No. 2 Chain Vibration Damper
    G00514524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE NO. CHAIN TENSIONER ASSEMBLY  . Refer to DISASSEMBLY .
  22. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. While holding the hexagonal portion of the camshaft with a wrench, remove the camshaft timing exhaust gear bolt.
      NOTE: Be sure not to remove the other 4 bolts. If any of them is removed, replace the camshaft timing exhaust gear assembly.
      Fig 9: Identifying Camshaft Timing Exhaust Gear Assembly Bolts
      G00514525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Hold the hexagonal portion of the intake camshaft with a wrench and turn it slightly counterclockwise to release the chain.
      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 tensioner. 

    3. Remove the camshaft timing exhaust gear assembly.
      NOTE: Keep the camshaft timing exhaust gear assembly horizontal while removing it from the camshaft.
  23. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. Temporarily install the camshaft timing exhaust gear assembly.
      1. 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.
        NOTE:
        • 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.
      Fig 10: Locating Knock Pin And Pin Hole
      G00514526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Inspect the camshaft timing exhaust gear lock.
      1. Check that the camshaft timing exhaust gear is locked.
    3. 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.
        Fig 11: Camshaft Timing Exhaust Gear Operation
        G00514527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Make a hole in the adhesive tape covering the oil hole as shown in the illustration. (Procedure B)
      3. Apply approximately 200 kPa (2.0 kgf/cm 2, 28 psi.) of air pressure to the hole made in procedure B to release the lock pin.
        NOTE:
        • 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.
        Fig 12: Identifying Hole In Adhesive Tape
        G00514528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Using a screwdriver with its tip taped, forcibly turn the camshaft timing exhaust gear in the retard direction (clockwise).
        NOTE:
        • 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.

        HINT: Depending on the air pressure applied, the camshaft timing exhaust gear may turn in the retard direction without assistance by hand. 

      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.
        Fig 13: Turning Camshaft Timing Gear Turns Smoothly With Screwdriver Tip Taped.
        G00514529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      6. Lock the camshaft timing exhaust gear.
        NOTE: Check that the camshaft timing exhaust gear assembly locks at the most advanced position (the most advanced position of its movable range) and cannot be rotated any further.
      7. Remove the adhesive tape from the No. 1 camshaft bearing cap.
    4. Remove the camshaft timing exhaust gear assembly.
      1. Remove the temporarily installed camshaft timing exhaust gear assembly.
  24. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Inspect the camshaft timing gear lock.
      1. Check that the camshaft timing gear is locked.
    2. 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.
        Fig 14: Adhesive Tape Sealing Area
        G00514530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Make a hole in the adhesive tape covering the oil hole as shown in the illustration. (Procedure A)
      3. Apply approximately 150 kPa (1.5 kgf/cm 2, 22psi.) of air pressure to the hole made in procedure A to release the lock pin.
        NOTE:
        • 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.
        Fig 15: Air Pressure
        G00514531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
        NOTE:
        • Do not lock the camshaft timing gear assembly.
        • If camshaft timing gear assembly is locked, release the lock pin again.
        Fig 16: Identifying Camshaft Timing Gear Turns Smoothly
        G00514532Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      6. Remove the adhesive tape from the No. 1 camshaft bearing cap.
  25. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY 
    1. While holding the hexagonal portion of the camshaft with a wrench, remove the camshaft timing gear assembly bolt with SST.

      SST: 09249-37010 

      NOTE:
      • Before removing the camshaft timing gear, make sure that the lock pin has been released.
      • Be sure not to remove the other 4 bolts.
      • If the camshaft timing gear assembly is to be reused, be sure to use it with the lock pin released.
      Fig 17: Removing Camshaft Timing Gear Assembly Bolt With SST
      G00514533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Release the chain and remove the camshaft timing gear assembly.
      NOTE: Keep the camshaft timing gear assembly horizontal while removing it from the camshaft.
    3. Suspend the chain with a string or equivalent.
      Fig 18: Identifying Chain
      G00514534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE CAMSHAFT BEARING CAP 
    1. Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
      NOTE: Be sure not to loosen the other 15 bearing cap bolts in this step.

      HINT: Arrange the removed parts in the correct order. 

      Fig 19: Identifying Camshaft Bearing Cap In Sequence
      G00514535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 15 bolts and bearing caps in the order shown in the illustration. Immediately after removing bearing caps, install service bolts and spacers in the order shown in the illustration.
      Fig 20: Removing Camshaft Bearings In Sequence
      G00514536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Service Bolt and Spacer (used to temporarily secure the camshaft housing) - -
      *a The removal order of the parts *b The installation order of the bolts and spacers for temporarily tightening the camshaft housing

      Torque: 27 N*m (275 (kgf*cm, 20ft*lbf) 

      NOTE:
      • If the bolts are loosened all at once, FIPG on the camshaft housing and cylinder head may peel off, resulting in oil oozing. Therefore, be sure to install the service bolts and spacers to one bearing cap at a time.
      • Do not install the bearing caps when installing the service bolts and spacers.

      HINT:  

      • Arrange the removed parts in the correct order.
      • Part number for the service bolts used to temporarily secure the camshaft housing: 91551-G0875 (15 bolts)
      • Part number for the service spacers used to temporarily secure the camshaft housing: 90387-12048 (15 spacers)

  27. REMOVE CAMSHAFT 
    1. Remove the camshaft from the camshaft housing.
    Fig 21: Identifying Camshaft Housing
    G00514537Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE NO. 2 CAMSHAFT 
    1. Remove the No. 2 camshaft from the camshaft housing.
    Fig 22: Identifying No. 2 Camshaft Housing
    G00514538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE NO. 1 CAMSHAFT BEARING 
    1. Remove the 2 No. 1 camshaft bearings from the No. 1 camshaft bearing cap.

      HINT:

      Arrange the removed parts in the correct order.

      Fig 23: Identifying No. 1 Camshaft Bearings
      G05398861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE NO. 2 CAMSHAFT BEARING 
    1. Remove the 2 No. 2 camshaft bearings from the camshaft housing.

      HINT:

      Arrange the removed parts in the correct order.

      Fig 24: Identifying No. 2 Camshaft Bearings
      G05398862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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