Removal

3UZ-FE ENGINE MECHANICAL: CAMSHAFT (for Bank 1): REMOVAL

REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

2. REMOVE NO. 1 AIR CLEANER INLET Removal
3. DRAIN ENGINE COOLANT Service and Repair
4. REMOVE V-BANK COVER Removal
5. REMOVE INTAKE AIR CONNECTOR PIPE Removal
6. REMOVE ENGINE UNDER COVER
7. DISCONNECT NO. 1 RADIATOR HOSE Removal
8. DISCONNECT NO. 2 RADIATOR HOSE Removal
9. DISCONNECT NO. 1 OIL COOLER INLET TUBE Removal
10. DISCONNECT NO. 1 OIL COOLER OUTLET TUBE Removal
11. REMOVE AIR CLEANER ASSEMBLY Removal
12. REMOVE RADIATOR ASSEMBLY Removal
13. REMOVE FAN AND GENERATOR V BELT Removal
14. REMOVE VANE PUMP ASSEMBLY Removal
15. REMOVE GENERATOR ASSEMBLY Removal
16. DISCONNECT COOLER COMPRESSOR ASSEMBLY Removal
17. REMOVE IGNITION COIL ASSEMBLY Removal
18. REMOVE SPARK PLUG
19. REMOVE NO. 3 TIMING BELT COVER SUB-ASSEMBLY RH Removal
20. REMOVE NO. 3 TIMING BELT COVER SUB-ASSEMBLY LH Removal
21. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY Removal
22. REMOVE NO. 2 TIMING BELT COVER SUB-ASSEMBLY Removal
23. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY Removal
24. REMOVE IDLER PULLEY ASSEMBLY Removal
25. REMOVE CRANKSHAFT PULLEY Removal
26. REMOVE NO. 1 TIMING BELT COVER Removal
27. REMOVE CRANKSHAFT POSITION SENSOR PLATE Removal
28. REMOVE TIMING GEAR COVER SPACER Removal
29. REMOVE TIMING BELT Removal
30. REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY Disassembly
31. REMOVE NO. 2 TIMING BELT IDLER SUB-ASSEMBLY Disassembly
32. REMOVE OIL DIPSTICK AND GUIDE [1][2]Removal
33. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY LH Removal
34. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

(a) Remove the 9 bolts, 9 seal washers and cylinder head cover.
35. WORK FOR PISTON AND VALVE DAMAGE PREVENTION

(a) Turn the crankshaft timing pulley counterclockwise by 45° and match the timing mark with the illustrated position.
HINT: When the No. 1 cylinder is positioned at 45° BTDC, the valve and piston do not interfere with each other even when the valve is fully open.
NOTE:
Be sure to match the cut part by turning it counterclockwise.

36. REMOVE CAMSHAFT TIMING PULLEY SUB-ASSEMBLY LH

(a) Hold the crankshaft with a wrench, and remove the 4 bolts and timing pulley.
NOTE:
Do not to remove the 4 "TORX" bolts indicated by the white arrows in the illustration. If the camshaft timing tube is removed, replace the camshaft timing tube assembly.

37. REMOVE NO. 3 CAMSHAFT AND NO. 4 CAMSHAFT
NOTE:
Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

(a) Remove the No. 3 and No. 4 camshafts.
(1) Bring the service bolt hole of the sub gear upward by turning the hexagon head portion of the exhaust No. 4 camshaft with a wrench.
(2) Secure the sub gear to the main gear with a service bolt.
Recommended service bolt:

HINT: When removing the camshaft, make sure that the torsional spring force of the sub gear has been eliminated by the above operation.

(3) Set a wrench to the hexagon head portion of the No. 4 camshaft. Rotate the wrench so that the timing marks (2 dot marks each) on the camshaft drive and driven main gears are aligned, as shown in the illustration.

(4) Uniformly loosen the 22 bearing cap bolts in several passes in the sequence shown in the illustration.
(5) Remove the 22 bearing cap bolts, 4 seal washers, oil feed pipe, 9 bearing caps, camshaft housing plug, oil control valve filter and 2 camshafts.
NOTICE:
- Do not forcibly pry the camshaft with a tool.
- Do not damage the reception part of the thrust on the cylinder head side.

38. REMOVE CAMSHAFT TIMING TUBE ASSEMBLY

(a) Mount the hexagon head portion of the camshaft in a vise between aluminum plates.
- Be careful not to damage the camshaft.
- Do not remove the 4 bolts shown in the illustration. The bolts determine the backlash of the gear in the timing tube. If any of the bolts are removed, install a new timing tube assembly.

(b) Remove the screw plug and seal washer.

(e) Using SST and a 5 mm hexagon wrench, remove the 4 bolts, drive gear and oil seal.
SST: 09960-10010
09962-01000
09963-00500
NOTE:
Be careful not to damage the camshaft.

39. REMOVE CAMSHAFT SUB GEAR

(a) Mount the hexagon head portion of the camshaft in a vice between aluminum plates.
NOTE:
Be careful not to damage the camshaft.

(b) Using SST, turn the sub gear clockwise and remove the service bolt.
SST: 09960-10010
09962-01000
09963-00500

(c) Using snap ring pliers, remove the snap ring.
(d) Remove the wave washer, sub gears and bolt washers.
HINT: Arrange the driven sub gears and bolt washers.

(e) Using a vernier caliper, measure the free distance between the bolt washer ends.
Free distance:
18.2 to 18.8 mm (0.712 to 0.740 in.)
If the free distance is not as specified, replace the bolt washer.