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Home >> Toyota >> 2016 >> Corolla S, Standard Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (Engine Mechanical (2ZR-FAE) - Service Information (1 Of 2) (Model Code: ZRE172)) >> Camshaft >> Removal [08/2013 - ] >> Procedure

Removal [08/2013 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL ENGINE TO ENGINE STAND 

    See step  50Refer to REMOVAL [08/2016 - ] 

  2. REMOVE ENGINE HANGER 

    See step  51 See step  51

  3. REMOVE INTAKE MANIFOLD 

    Refer to REMOVAL [08/2013 - ]

  4. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 7

  5. REMOVE WIRE HARNESS CLAMP BRACKET 

    Refer to PROCEDURE - Step 9 Refer to PROCEDURE - Step 9

  6. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE 

    See step  8Refer to PROCEDURE - Step 8

  7. REMOVE WATER INLET HOSE 

    See step  17Refer to PROCEDURE - Step 17

  8. DISCONNECT NO. 3 WATER BY-PASS HOSE 

    See step  14Refer to PROCEDURE - Step 14

  9. REMOVE VACUUM PUMP ASSEMBLY 

    Refer to REMOVAL [08/2013 - ]

  10. REMOVE NO. 1 VACUUM PUMP BRACKET 

    See step  22Refer to PROCEDURE - Step 22

  11. REMOVE IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  12. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 13 Refer to PROCEDURE - Step 13 Refer to PROCEDURE - Step 13

  13. REMOVE CYLINDER HEAD COVER GASKET 

    Refer to PROCEDURE - Step 14 Refer to PROCEDURE - Step 14 Refer to PROCEDURE - Step 14

  14. REMOVE SPARK PLUG TUBE GASKET 

    Refer to PROCEDURE - Step 15 Refer to PROCEDURE - Step 15 Refer to PROCEDURE - Step 15

  15. SET NO. 1 CYLINDER TO TDC/COMPRESSION 
    1. Turn the crankshaft pulley until its timing notch and timing mark "0" of the timing chain cover sub-assembly are aligned.
      GTY435931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark
      *b Timing Notch
    2. Check that timing marks on both the camshaft timing exhaust gear assembly and camshaft timing gear assembly are facing upward as shown in the illustration.

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

  16. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY 

    See step  24Refer to PROCEDURE - Step 24

  17. REMOVE CRANKSHAFT PULLEY 

    See step  5 See step  5

  18. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Remove the 2 nuts, bracket, No. 1 chain tensioner assembly and gasket.
      GTY164836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

  19. REMOVE STUD BOLT 

    Refer to PROCEDURE - Step 21 Refer to PROCEDURE - Step 21 Refer to PROCEDURE - Step 21

  20. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 22 Refer to PROCEDURE - Step 22 Refer to PROCEDURE - Step 22

  21. REMOVE TIMING CHAIN COVER OIL SEAL 

    Refer to PROCEDURE - Step 23 Refer to PROCEDURE - Step 23 Refer to PROCEDURE - Step 23

  22. REMOVE CHAIN TENSIONER SLIPPER 
    1. Remove the chain tensioner slipper from the cylinder block sub-assembly.
      GTY426617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE NO. 1 CHAIN VIBRATION DAMPER 
    1. Remove the 2 bolts and No. 1 chain vibration damper.
      GTY429203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE CHAIN SUB-ASSEMBLY 
    1. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly counterclockwise to loosen the chain sub-assembly between the camshaft timing exhaust gear assembly and camshaft timing gear assembly.
      GTY429205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. With the chain loosened, release the chain sub-assembly from the camshaft timing gear assembly and place it on the camshaft timing gear assembly.

      HINT: 

      Be sure to release the chain sub-assembly from the sprocket completely.

    3. Turn the camshaft clockwise to return it to the original position and remove the chain sub-assembly.
  25. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Inspect the lock of the camshaft timing gear assembly.
    2. After cleaning the VVT oil hole in 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.
      GTY444211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive Tape
      *b Adhesive Tape Sealing Area
      *c Prick a Hole
      NOTE:

      Be sure to cover the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

    3. Prick a hole in the tape covering the oil hole as shown in the illustration. (Procedure A)
    4. 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.
      GTY426627Courtesy 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.
    5. Forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

      HINT: 

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

    6. Turn the camshaft timing gear assembly within its movable range (30 to 32°) 2 or 3 times without turning it to the most retarded position. Make sure that the camshaft timing gear assembly turns smoothly.
      GTY426618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the adhesive tape from the No. 1 camshaft bearing cap.
  26. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. Check the lock of the camshaft timing exhaust gear assembly.
    2. After cleaning the VVT oil hole in the exhaust 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.
      GTY447613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive Tape
      *b Adhesive Tape Sealing Area
      *c Prick a Hole
      NOTE:

      Be sure to cover the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

    3. Prick a hole in the tape covering the oil hole as shown in the illustration. (Procedure A)
    4. Apply approximately 200 kPa (2.0 kgf/cm2 , 28 psi) of air pressure to the hole pricked in procedure A to release the lock pin.
      GTY426625Courtesy 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.
    5. Using a screwdriver with its tip wrapped with tape, forcibly turn the camshaft timing exhaust gear assembly in the retard direction (clockwise).
      NOTE:
      • Be sure to keep the camshaft timing exhaust gear assembly in the retard direction using a screwdriver. If the gear is released, it will return to the most advanced position automatically due to the force from the spring.
      • Do not damage the camshaft timing exhaust gear assembly.
    6. Using a screwdriver with its tip wrapped with tape, turn the camshaft timing exhaust gear assembly within its movable range (24 to 26°) 2 or 3 times without turning it to the most advanced position. Make sure that the camshaft timing exhaust gear assembly turns smoothly.
      GTY451008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the adhesive tape from the No. 1 camshaft bearing cap.
  27. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Remove the bolt while holding the hexagonal portion of the camshaft, and then remove the camshaft timing gear assembly.
      GTY453718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt
      *b Do not remove
      NOTE:
      • Before removing the camshaft timing gear assembly, 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.
  28. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. Remove the flange bolt while holding the hexagonal portion of the camshaft, and then remove the camshaft timing exhaust gear assembly.
      GTY429082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt
      *b Do not remove
      NOTE:
      • Be sure not to remove the other 4 bolts.
      • Keep the camshaft timing exhaust gear assembly horizontal while removing it from the camshaft.
  29. REMOVE VALVE ROCKER ARM LOST MOTION DAMPER SUB-ASSEMBLY 
    1. Remove the 2 bolts and valve rocker arm lost motion damper sub-assembly.
      GTY456104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Shim
      NOTE:
      • Make sure the camshaft housing sub-assembly is installed to the cylinder head sub-assembly when removing or installing a valve rocker arm lost motion damper sub-assembly.
      • If a valve rocker arm lost motion damper sub-assembly is removed, do not remove the camshaft housing sub-assembly.
      • Do not remove the shims. If a shim is removed, replace the camshaft housing sub-assembly as engine malfunctions may result from irregular valve timing.
  30. INSTALL VALVE ROCKER ARM LOST MOTION DAMPER SUB-ASSEMBLY 
    1. Install the valve rocker arm lost motion damper sub-assembly with the 2 bolts. Uniformly tighten the bolts.
      GTY437851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hole for Engine Oil

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    2. Add engine oil into the hole for engine oil.
  31. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY 
    NOTE:
    • The camshaft housing sub-assembly is replaced with an assembled unit that includes the camshaft housing sub-assembly, camshafts, camshaft bearing caps, valve rocker shaft and valve rocker arm lost motion damper sub-assembly. If disassembled, replace the camshaft housing sub-assembly.
    • The camshafts cannot be replaced by themselves.
      GTY426281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Continuously Variable Valve Lift Controller Assembly *2 Camshaft Housing Sub-assembly
      *a Set of parts that are replaced together - -
    1. Uniformly loosen and remove the 17 bearing cap bolts in the order shown in the illustration.
      Fig 1: Camshaft Bearing Caps Bolt Loosening Sequence
      GTY454485Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

    2. Using a screwdriver, remove the camshaft housing sub-assembly by prying between the cylinder head sub-assembly and camshaft housing sub-assembly.
      GTY427596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape

      HINT: 

      Tape the screwdriver tip before use.

      NOTE:

      Be careful not to damage the contact surfaces of the cylinder head sub-assembly and camshaft housing sub-assembly.

  32. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  33. REMOVE VALVE LASH ADJUSTER ASSEMBLY 

    Refer to PROCEDURE - Step 2

  34. INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  35. INSPECT VALVE LASH ADJUSTER ASSEMBLY 

    Refer to PROCEDURE - Step 2

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