Camshaft: Service and Repair

CAMSHAFT (2AZ-FE)
REPLACEMENT





NOTICE: When disconnecting the battery negative terminal, initialize the system(s) shown after the terminal is reconnected.

1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE FRONT WHEEL RH
3. REMOVE ENGINE UNDER COVER RH
4. REMOVE ENGINE UNDER COVER LH
5. REMOVE FRONT FENDER APRON SEAL RH
6. REMOVE ENGINE COVER SUB-ASSEMBLY NO.1
7. REMOVE FAN AND GENERATOR V-BELT
SST 09249-63010
8. SEPARATE VANE PUMP ASSEMBLY
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9. REMOVE ENGINE MOUNTING INSULATOR RH
10. REMOVE IGNITION COIL ASSEMBLY
11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
12. SET NO. 1 CYLINDER TO TDC/COMPRESSION





13. REMOVE NO.2 CAMSHAFT
a. Place paint marks on the chain and camshaft timing gears.





b. Remove the bolt.
c. Disconnect the wire harness protector clamp.





d. Remove the 2 nuts, chain tensioner and gasket.

NOTICE: Do not turn the crankshaft without the chain tensioner.





e. While holding the camshaft with a wrench, loosen the camshaft timing gear set bolt.

NOTICE: Be careful not to damage the valve lifter.





f. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
g. Remove the 5 bearing caps.





h. While holding the No. 2 camshaft by hard, remove the camshaft timing gear set bolt.
i. Remove the camshaft timing gear from the No. 2 camshaft with the timing chain wrapped.
j. Remove the camshaft timing gear from the timing chain.





14. REMOVE CAMSHAFT
a. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
b. Remove the 5 bearing caps.
c. Remove the camshaft and camshaft timing gear while holding the timing chain by hand.





d. Tie the timing chain with a string as shown in the illustration.

NOTICE: Be careful not to drop anything inside the timing chain cover.





15. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
a. Clamp the camshaft in a vise, and make sure that the camshaft timing gear does not rotate.
b. Cover all the oil ports with vinyl tape except the advance side port shown in the illustration.





c. Apply air pressure to the oil path of 100 kPa (1.0 kgf/cm2, 14 psi), then turn the camshaft timing gear to the advance direction (counterclockwise) by hand.

CAUTION: Cover the paths with a shop rag to avoid oil splashes.

HINT: Depending on the air pressure, the camshaft timing gear will turn to the advance angle side without applying force by hand. Also, under the condition that the pressure can be hardly applied because of the air leakage from the port, there may be the case that the lock pin could be hardly released.





d. Remove the fringe bolt of the camshaft timing gear.

NOTICE:
- 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.





16. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
a. Put the camshaft timing gear and camshaft together with the straight pin off the key groove.
b. Turn the camshaft timing gear in the left as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.

CAUTION: Be sure not to turn the camshaft timing gear to the retard angle side (the right angle).

c. Check that there is no clearance between the gear fringe and camshaft.
d. Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)
e. Check that the camshaft timing gear can move to the retard angle side (the right direction) and is locked in the most retarded position.
17. INSTALL CAMSHAFT
a. Apply a light coat of engine oil to the journal portion of the camshaft.





b. Install the timing chain onto the camshaft timing gear with the paint mark aligned with the timing mark on the camshaft timing gear as shown in the illustration.





c. Examine the front marks and numbers and check that the sequence order is as shown in the illustration. Then install the bearing caps onto the cylinder head.
d. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
e. Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.
Torque:
29.5 Nm (301 kgf-cm, 22 ft. lbs.) for bearing cap No. 1
9.0 Nm (92 kgf-cm, 80 inch lbs.) for bearing cap No. 3
18. INSTALL NO.2 CAMSHAFT
a. Apply a light coat of engine oil to the journal portion of the No. 2 camshaft.





b. Put the No. 2 camshaft on the cylinder head with the paint mark of the chain aligned with the timing mark on the camshaft timing gear.





c. While holding the No. 2 camshaft by hand, temporally tighten the camshaft timing gear set bolt.





d. Examine the front marks and numbers and check that the sequence order is as shown in the illustration. Then install the bearing caps onto the cylinder head.
e. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
f. Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.
Torque:
29.5 Nm (301 kgf-cm, 22 ft. lbs.) for bearing cap No. 2
9.0 Nm (92 kgf-cm, 80 inch lbs.) for bearing cap No. 3





g. While holding the camshaft with a wrench, tighten the camshaft timing gear set bolt.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)

NOTICE: Be careful not to damage the valve lifter.





h. Check that the paint marks on the chain and camshaft timing gears are aligned. Also, check that the crankshaft pulley groove is aligned with the timing mark "0" of the timing chain cover.





i. Install the chain tensioner.
1. Release the ratchet pawl, then fully push in the plunger and hook the hook to the pin so that the plunger is located in position.





2. Install a new gasket and the chain tensioner with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

NOTICE: When installing the chain tensioner, set the hook again if the hook releases the plunger.





3. Turn the crankshaft counterclockwise, then disconnect the plunger knock pin from the hook.





4. Turn the crankshaft clockwise, then check that the plunger is extended.





5. Connect the wire harness protector clamp.
6. Install the bolt.
Torque: 8.4 Nm (85 kgf-cm, 74 inch lbs.)
19. CHECK VALVE CLEARANCE
20. ADJUST VALVE CLEARANCE
21. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
22. INSTALL IGNITION COIL ASSEMBLY
23. INSTALL ENGINE MOUNTING INSULATOR RH
24. INSTALL VANE PUMP ASSEMBLY
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25. INSTALL FAN AND GENERATOR V-BELT
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26. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
27. CHECK FOR ENGINE OIL LEAKAGE
28. INSTALL ENGINE COVER SUB-ASSEMBLY NO.1
29. INSTALL FRONT FENDER APRON SEAL RH
30. INSTALL ENGINE UNDER COVER LH
31. INSTALL ENGINE UNDER COVER RH
32. INSTALL FRONT WHEEL RH
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)