Removal

3UZ-FE ENGINE MECHANICAL: CAMSHAFT (for Bank 2): 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. REMOVE ENGINE UNDER COVER

4. DRAIN ENGINE COOLANT Service and Repair

5. REMOVE V-BANK COVER Removal

6. REMOVE INTAKE AIR CONNECTOR PIPE Removal

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 & 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 CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY RH Removal

33. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH





(a) Remove the bolt, and disconnect the wire harness clamp from the camshaft bearing cap.

(b) Remove the bolt, and disconnect the engine wire protector from the cylinder head cover.

(c) Remove the 9 bolts, 9 seal washers and cylinder head cover.





34. WORK FOR PISTON AND VALVE DAMAGE PREVENTION





(a) Turn the crankshaft timing pulley counterclockwise at 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.

NOTICE:
Be sure to match the cut part by turning it counterclockwise.

35. REMOVE CAMSHAFT TIMING PULLEY SUB-ASSEMBLY RH





(a) Hold the crankshaft with a wrench, and remove the 4 bolts and timing pulley.

NOTICE:
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.

36. REMOVE CAMSHAFT AND NO. 2 CAMSHAFT

NOTICE:
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 camshaft and No. 2 camshaft.





(1) Bring the service bolt hole of the sub gear upward by turning the hexagon head portion of the No. 2 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. 2 camshaft. Rotate the wrench so that the timing mark (1 dot mark) on the camshaft main gear is moved approximately 10°, 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.
37. REMOVE CAMSHAFT TIMING TUBE ASSEMBLY

(a) Mount the hexagon head portion of the camshaft in a vise between aluminum plates.





NOTICE:
* 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.

(c) Using a 10 mm hexagon wrench, remove the bolt.





(d) Pull put the timing tube and drive gear from the camshaft.

(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

NOTICE:
Be careful not to damage the camshaft.

38. REMOVE CAMSHAFT SUB GEAR

(a) Mount the hexagon head portion of the camshaft in a vice between aluminum plates.





NOTICE:
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.)

(e) If the free distance is not as specified, replace the bolt washer.