Engine Mechanical (2ZR-FE): Camshaft: Removal

REMOVE FRONT WIPER ARM HEAD CAP . Refer to REMOVAL - Step 1
REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH . Refer to REMOVAL - Step 2
REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH . Refer to REMOVAL - Step 3
REMOVE HOOD TO COWL TOP SEAL . Refer to REMOVAL - Step 4
REMOVE CENTER NO. 1 COWL TOP VENTILATOR LOUVER . Refer to REMOVAL - Step 5
REMOVE COWL TOP VENTILATOR LOUVER LH . Refer to REMOVAL - Step 6
REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY . Refer to REMOVAL - Step 7
REMOVE OUTER COWL TOP PANEL (for TMC Made) . Refer to REMOVAL - Step 14
REMOVE OUTER COWL TOP PANEL (except TMC Made) . Refer to REMOVAL - Step 15
REMOVE NO. 2 CYLINDER HEAD COVER See step 10
REMOVE IGNITION COIL ASSEMBLY . Refer to REMOVAL - Step 2
REMOVE RADIO SETTING CONDENSER See step 19
DISCONNECT NO. 2 VENTILATION HOSE
1. Disconnect the No. 2 ventilation hose.
  
  Fig 1: Locating No. 2 Ventilation Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT ENGINE WIRE
1. Remove the 2 bolts, 5 connectors, 5 clamps and disconnect the engine wire.
  
  Fig 2: Identifying Engine Wire Bolts, Connectors & Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR TUBE
1. Remove the 2 bolts, 4 hoses and air tube assembly.
  
  Fig 3: Identifying Air Tube Assembly Bolts & Hoses
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY See step 8
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 Crankshaft Pulley & Timing Chain Cover
  Courtesy 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 marks 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 On Camshaft Timing Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 CHAIN VIBRATION DAMPER
1. Using SST, remove the 2 bolts and No. 2 chain vibration damper from the camshaft bearing cap.
  
  Fig 6: Locating Bolts And No 2 Chain Vibration Damper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09961-00950
REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY See step 13
REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
1. While holding the hexagonal portion of the No. 2 camshaft with a wrench, loosen the camshaft timing exhaust gear bolt with SST.
  
  Fig 7: Removing Camshaft Timing Exhaust Gear Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - 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.
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 tensioned.
3. While removing the chain, pull out the camshaft timing exhaust gear assembly horizontally and then upward with the bolts installed.
  
  Fig 8: Removing Camshaft Timing Exhaust Gear Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
1. Temporarily install the camshaft timing exhaust gear assembly.
  1. Install the bolt to the camshaft timing exhaust gear assembly.
    
    Fig 9: Checking Camshaft Timing Exhaust Gear
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
    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.
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.
    
    Fig 10: Identifying Adhesive Tape Applying Area
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    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 200 kPa (2.0 kgf/cm² , 28 psi.) of air pressure to the hole made in procedure B to release the lock pin.
    
    Fig 11: Releasing Lock Pin By Applying Air Pressure To Hole
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
  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 12: Checking That Camshaft Timing Gear Turns Smoothly
    Courtesy 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.
    
    Fig 13: Removing Camshaft Timing Exhaust Gear Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
    
    Fig 14: Identifying Adhesive Tape Applying Area
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    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 150 kPa (1.5 kgf/cm² , 22 psi.) of air pressure to the hole made in procedure A to release the lock pin.
    
    Fig 15: Applying Air Pressure to Release Lock Pin
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
  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.
    
    Fig 16: Removing Adhesive Tape From No. 1 Camshaft Bearing Cap
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    Do not lock the camshaft timing gear assembly.
    
    If camshaft timing gear assembly is locked, release the lock pin again.
  6. Remove the adhesive tape from the No. 1 camshaft bearing cap.

REMOVE CAMSHAFT BEARING CAP

Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

Fig 17: Loosening Sequence For Bearing Cap Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:
Be sure not to loosen the other 15 bearing cap bolts in this step.

HINT:

Arrange the removed parts in the correct order.

Remove the 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 18: Loosening/Tightening Order For Bolts And Bearing Caps

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*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, 20 ft.*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 washers used to temporarily secure the camshaft housing: 90387-12048 (15 spacers)

REMOVE NO. 2 CAMSHAFT
1. Remove the No. 2 camshaft from the camshaft housing.
  
  Fig 19: View Of No. 2 Camshaft From Camshaft Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT
1. Hold up the chain and remove the camshaft from the camshaft housing.
  
  Fig 20: View Of Camshaft, Chain And Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Suspend the chain with a string or equivalent.
  
  Fig 21: Suspending Chain With String Or Equivalent
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
1. Secure the hexagonal portion of the camshaft in a soft jaw vise.
2. Remove the flange bolt and the camshaft timing gear assembly.
  
  Fig 22: Identifying Flange Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
  - Keep the camshaft timing gear assembly horizontal while removing it from the camshaft.
  - If the camshaft timing gear assembly is to be reused, be sure to use it with the lock pin released.
REMOVE NO. 1 CAMSHAFT BEARING
1. Remove the 2 No. 1 camshaft bearings.
  
  Fig 23: Identifying No. 1 Camshaft Bearings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Arrange the removed parts in the correct order.
REMOVE NO. 2 CAMSHAFT BEARING
1. Remove the 2 No. 2 camshaft bearings.
  
  Fig 24: View Of No. 2 Camshaft Bearings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Arrange the removed parts in the correct order.