Removal

4GR-FSE ENGINE MECHANICAL: CAMSHAFT: REMOVAL

1. REMOVE BATTERY

Removal.

2. REMOVE FUEL PUMP ASSEMBLY

Removal.

3. REMOVE GENERATOR ASSEMBLY

Removal.

4. REMOVE NO. 1 ENGINE COVER Removal

5. REMOVE INJECTOR DRIVER Removal

6. REMOVE IGNITION COIL ASSEMBLY Removal

7. REMOVE SPARK PLUG Removal

8. REMOVE NO. 1 OIL PIPE Disassembly

9. REMOVE NO. 2 OIL PIPE Disassembly

10. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

(a) Remove the bolt and ground wire.

HINT
* Make sure the cylinder head cover is clear of all wiring and connectors.
* Make sure the removed parts are returned to the same places they were removed from.

(b) Remove the 12 bolts, head cover sub-assembly LH and gasket.

Text in Illustration

NOTICE:
The baffle plate is located on the back of the portion shown in the illustration. Do not damage the baffle plate when removing the head cover.

(c) Remove the 3 gaskets.

11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Remove the bolt and ground wire.

12. REMOVE TIMING CHAIN COVER PLATE

(a) Remove the 4 bolts, timing chain cover plate and gasket.

13. SET NO. 1 CYLINDER TO TDC/COMPRESSION

(a) Turn the crankshaft pulley and align the notch with the "0" timing mark of the timing chain cover.

(b) Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing caps as shown in the illustration.

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HINT
If the marks are not aligned, turn the crankshaft again to align the marks.

(c) Place paint marks on the chain in alignment with the timing marks on each camshaft timing gear and bearing cap.

HINT
Be sure to place the paint marks on 2 links of the chain and on the sprockets of the camshaft timing gears at the locations of the timing marks of the camshaft timing gears.

14. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Turn the crankshaft approximately 30° counterclockwise so that there is some slack in the chain.

HINT
This prevents the valves and pistons from interfering with each other.

(b) Align the hole in the lever of the tensioner with the hole in the tensioner body as shown in the illustration, and then insert a pin with a diameter of 1.27 mm (0.0500 in.) into the hole.

Text in Illustration

(d) Remove the 2 bolts and chain tensioner.

NOTICE:
Do not drop the No. 1 chain tensioner assembly or bolts into the timing chain cover.

15. SEPARATE CHAIN SUB-ASSEMBLY

(a) Turn the crankshaft clockwise until it is in the position shown in the illustration so that there is some slack in the chain between the banks.

CAUTION:
As the camshafts turn suddenly, do not touch the camshafts or camshaft timing gears.

HINT
When turning the crankshaft, engine oil may spray out of the oil holes.

(b) Turn the crankshaft clockwise until it is in the position shown in the illustration so that the chain can be removed easily.

HINT
When turning the crankshaft, engine oil may spray out of the oil holes.

(c) Remove the chain from the sprocket of the camshaft timing gear and set it on the camshaft timing gear.

CAUTION:
As the camshaft may turn suddenly and pinch your fingers when the chain is removed, pinch the chain and lift it upward to remove it from the sprocket.

16. REMOVE CAMSHAFT BEARING CAP (for Bank 1)

(a) Remove the bolts and bearing caps in the order shown in the illustration. Immediately after removing bearing caps, install service bolts and washers in the order shown in the illustration.

Text in Illustration

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

HINT
* Arrange the removed parts so that they can be reinstalled in their original locations.
* Part number for the service bolts used to temporarily secure the camshaft housing: 91551-G0845 (9 bolts)
* Part number for the service washers used to temporarily secure the camshaft housing: 90201-12028 (18 washers)

NOTICE:
* Do not install the bearing caps when installing the service bolts and washers.
* Be sure to follow the numerical order when performing this procedure.
* Do not allow the service bolts and washers to contact the camshaft.
* Do not drop the service bolts and washers into the cylinder head.

17. REMOVE NO. 2 CAMSHAFT

(a) Remove the bolt of the No. 2 chain tensioner assembly.

(b) Remove the No. 2 chain tensioner assembly while lifting up the No. 2 camshaft.

(c) While lifting up the No. 2 camshaft, pass it through the No. 2 chain and pull it out towards the front of the vehicle to remove it.

18. REMOVE CAMSHAFT

(a) Lift up the rear of the camshaft so that it is at an angle.

(b) Remove the chain from the camshaft timing gear and pull out the camshaft and No. 2 chain towards the rear of the vehicle to remove them.

NOTICE:
Do not drop the chain into the gap between the engine and cover.

(c) Suspend the chain with a string or equivalent.

19. SEPARATE CHAIN SUB-ASSEMBLY

(a) Turn the crankshaft counterclockwise and align the notch with the "0" timing mark of the timing chain cover.

(b) Remove the chain from the sprocket of the camshaft timing gear and set it on the camshaft timing gear.

CAUTION:
As the camshaft may turn suddenly and pinch your fingers when the chain is removed, pinch the chain and lift it upward to remove it from the sprocket.

20. REMOVE CAMSHAFT BEARING CAP (for Bank 2)

(a) Remove the bolts and bearing caps in the order shown in the illustration. Immediately after removing bearing caps, install service bolts and washers in the order shown in the illustration.

Text in Illustration

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

HINT
* Arrange the removed parts so that they can be reinstalled in their original locations.
* Part number for the service bolts used to temporarily secure the camshaft housing: 91551-G0845 (8 bolts)
* Part number for the service washers used to temporarily secure the camshaft housing: 90201-12028 (16 washers)

NOTICE:
* Do not install the bearing caps when installing the service bolts and washers.
* Be sure to follow the numerical order when performing this procedure.
* Do not allow the service bolts and washers to contact the camshaft.
* Do not drop the service bolts and washers into the cylinder head.

21. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY

(a) Remove the bolt of the No. 3 chain tensioner assembly.

(b) Remove the No. 3 chain tensioner assembly while lifting up the No. 4 camshaft.

(c) While lifting up the No. 4 camshaft, pass it through the No. 2 chain and pull it out towards the front of the vehicle to remove it.

22. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY

(a) Lift up the rear of the camshaft so that it is at an angle.

(b) Remove the chain from the camshaft timing gear and pull out the No. 3 camshaft and No. 2 chain towards the rear of the vehicle to remove them.

NOTICE:
Do not drop the chain into the gap between the engine and cover.

(c) Suspend the chain with a string or equivalent.

23. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

(a) Check the lock of the camshaft timing gear assembly.

(1) Clamp the camshaft in a vise, and confirm that the camshaft timing gear assembly is locked.

NOTICE:
Be careful not to damage the camshaft.

(b) Release the lock pin.

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(1) Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

HINT
The 2 advance side paths are located in the camshaft groove. Plug one of the paths with a rubber piece.

(2) Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path, as shown in the illustration.

(3) Apply approximately 200 kPa (2.0 kgf/cm2, 28 psi) of air pressure to the 2 opened paths.

Text in Illustration

CAUTION:
Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying.

(4) Check that the camshaft timing gear assembly rotates in the advance direction when reducing the air pressure applied to the retard side path.

Text in Illustration

HINT
This operation releases the lock pin at the most retarded position.

(5) When the camshaft timing gear assembly reaches the most advanced position, release the air pressure first from the retard side path and next from the advance side path.

NOTICE:
Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin.

(c) Check for smooth rotation.

(1) Turn the camshaft timing gear assembly within its movable range (21°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly.

NOTICE:
Do not use air pressure to perform the smooth operation check.

(d) Check the lock in the most retarded position.

(1) Confirm that the camshaft timing gear assembly locks at the most retarded position.

(e) Remove the flange bolt and camshaft timing gear assembly.

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NOTICE:
* Do not remove the other 3 bolts.
* If planning to reuse the camshaft timing gear, be sure to release the straight pin lock before installing the camshaft timing gear.

24. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

(a) Check the camshaft timing exhaust gear lock.

(1) Make sure that the camshaft timing exhaust gear assembly locks.

(b) Release the lock pin.

Text in Illustration

CAUTION:
Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying.

(4) Make sure that the camshaft timing exhaust gear assembly rotates in the retard direction when reducing the air pressure applied to the advance side path.

Text in Illustration

HINT
The lock pin is released and the camshaft timing exhaust gear assembly turns in the retard direction.

(5) When the camshaft timing exhaust gear assembly moves to the most retarded position, release the air pressure first from the advance side path, and then release the air pressure from the retard side path.

NOTICE:
Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear assembly may abruptly shift in the advance direction and break the lock pin or other parts.

(c) Check for smooth rotation.

(1) Turn the camshaft timing exhaust gear assembly within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear assembly turns smoothly.

NOTICE:
When the air pressure is released from the advance side path and then from the retard side path, the gear assembly automatically returns to the most advanced position due to the advance assist spring operation and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check.

(d) Check the lock at the most advanced position.

(1) Make sure that the camshaft timing exhaust gear assembly locks at the most advanced position.

(e) Remove the flange bolt and camshaft timing exhaust gear assembly.

Text in Illustration

NOTICE:
* Be sure not to remove the other 4 bolts.
* If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.