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

REMOVE ENGINE UNDER COVER RH
REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (See REMOVAL )
REMOVE IGNITION COIL ASSEMBLY (See REMOVAL )
REMOVE SPARK PLUG (See REMOVAL )
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
1. Remove the 2 ventilation hoses from the cylinder head cover sub-assembly.
  
  Fig 1: Locating Ventilation Hoses
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 bolts and separate the 2 wire harness brackets.
  
  Fig 2: Locating Wire Harness Brackets Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 8 bolts and 2 nuts, then remove the cylinder head cover sub-assembly and gasket.
  
  Fig 3: Locating Cylinder Head Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SET NO. 1 CYLINDER TO TDC/COMPRESSION
1. Turn the crankshaft pulley until the groove and the timing mark "0" on the timing chain cover are aligned.
2. Check that each timing mark on the camshaft timing gear and sprocket is aligned with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration.
  If not, turn the crankshaft pulley 1 revolution (360°) to align the timing marks as illustrated.
3. Place paint marks on the chain in alignment with the timing marks on the camshaft timing gear and camshaft timing sprocket.
Fig 4: Identifying Timing Mark On Camshaft Timing Gear And Sprocket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (See REMOVAL )
LOOSEN CAMSHAFT TIMING GEAR OR SPROCKET
1. While holding the No. 2 camshaft with a wrench, loosen the No. 2 camshaft timing set bolt.
Fig 5: Loosening Camshaft Timing Set Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 CAMSHAFT
1. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
2. Remove the 5 bearing caps.
  
  Fig 6: Identifying Bearing Cap Bolts Removing Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. While holding the No. 2 camshaft by hand, remove the camshaft timing sprocket set bolt.
4. Remove the camshaft timing sprocket from the No. 2 camshaft with the timing chain placed around the sprocket.
5. Remove the camshaft timing sprocket from the timing chain.
  
  Fig 7: Removing Camshaft Timing Sprocket From Timing Chain
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT
1. In several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
2. Remove the 5 bearing caps.
3. Remove the camshaft and camshaft timing gear assembly while holding the timing chain by hand.
  
  Fig 8: Identifying Bearing Cap Bolts Removing Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Support the timing chain with a string to prevent it from slipping off the crankshaft sprocket as shown in the illustration.
  NOTE: Be careful not to drop anything inside the timing chain cover.
  
  Fig 9: Supporting Timing Chain With String
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
1. Clamp the camshaft in a vise, and make sure that the camshaft timing gear assembly does not rotate.
2. Cover all the oil paths with vinyl tape except the advance side path shown in the illustration.
  
  Fig 10: Clamping Camshaft In Vise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply air pressure of 150 kPa (1.5 kgf/cm² , 22 psi) to the opened oil path, then turn the camshaft timing gear assembly to the advance direction (counterclockwise) by hand.
  CAUTION: Cover the paths with a piece of cloth to avoid oil splashes.
  
  Fig 11: Applying Air Pressure Of Opened Oil Path
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Depending on the air pressure, the camshaft timing gear assembly may turn to the advance side without applying force by hand. Also, if the pressure is difficult to apply because of air leakage from a path, the lock pin may be difficult to release.
4. Remove the flange bolt of the camshaft timing gear.
  NOTE:
  - Be sure not to remove the other 4 bolts.
  - When reusing the camshaft timing gear, release the straight pin lock first, then install the gear.
  Fig 12: Identifying Camshaft Timing Gear And Flange Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002