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Home >> Scion >> 2009 >> xD L4-1.8L (2ZR-FE) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Camshaft, Lifters and Push Rods >> Camshaft >> Service and Repair >> Removal

Removal








2ZR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE
Precaution
2. REMOVE BATTERY Removal
3. REMOVE BATTERY TRAY
4. REMOVE FRONT WHEELS
5. REMOVE ENGINE UNDER COVER LH
6. REMOVE ENGINE UNDER COVER RH
7. DRAIN ENGINE COOLANT Service and Repair
8. DRAIN ENGINE OIL Replacement
9. REMOVE FRONT WIPER ARM HEAD CAP Removal
10. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH Removal
11. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH Removal
12. REMOVE HOOD TO COWL TOP SEAL Removal
13. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Removal
14. REMOVE COWL TOP VENTILATOR LOUVER LH Removal
15. REMOVE FRONT WIPER MOTOR AND LINK Removal
16. REMOVE FRONT AIR SHUTTER SEAL RH Removal
17. REMOVE OUTER COWL TOP PANEL Removal
18. REMOVE AIR CLEANER ASSEMBLY Removal
19. REMOVE AIR CLEANER BRACKET Removal
20. REMOVE BATTERY CARRIER Removal
21. REMOVE NO. 2 CYLINDER HEAD COVER Removal
22. REMOVE FAN & GENERATOR V BELT Removal
23. REMOVE NO. 2 RADIATOR HOSE Removal
24. DISCONNECT NO. 1 RADIATOR HOSE Removal
25. REMOVE FRONT BUMPER COVER Removal
26. DISCONNECT NO. 1 OIL COOLER OUTLET HOSE (for Automatic Transaxle) Removal
27. DISCONNECT NO. 2 OIL COOLER INLET HOSE (for Automatic Transaxle) Removal
28. REMOVE HOOD LOCK ASSEMBLY Removal
29. REMOVE NO. 1 COOLER COVER Removal
30. REMOVE UPPER RADIATOR SUPPORT ABSORBER Disassembly
31. REMOVE UPPER RADIATOR SUPPORT SUB-ASSEMBLY Removal
32. REMOVE RADIATOR ASSEMBLY Removal
33. SEPARATE WITH PULLEY COMPRESSOR ASSEMBLY Removal
34. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) Removal
35. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) Removal
36. SEPARATE UNION TO CHECK VALVE HOSE Removal
37. SEPARATE NO. 1 FUEL VAPOR FEED HOSE Removal
38. DISCONNECT ENGINE WIRE Removal
39. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) Removal
40. DISCONNECT HEATER WATER HOSE INLET A Removal
41. DISCONNECT FUEL TUBE SUB-ASSEMBLY Removal
42. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) Removal
43. REMOVE COLUMN HOLE COVER SILENCER SHEET Removal
44. SEPARATE STEERING SLIDING YOKE SUB-ASSEMBLY Removal
45. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY Removal
46. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) Removal
47. REMOVE CONSOLE PANEL UPPER Removal
48. REMOVE CONSOLE BOX COVER REAR Removal
49. REMOVE CONSOLE BOX CARPET Removal
50. REMOVE REAR CONSOLE BOX ASSEMBLY Removal
51. REMOVE FRONT CONSOLE BOX Removal
52. REMOVE FRONT FLOOR BRACE CENTER Removal
53. REMOVE FRONT EXHAUST PIPE ASSEMBLY Removal
54. REMOVE FRONT AXLE SHAFT LH NUT Removal
55. REMOVE FRONT AXLE SHAFT RH NUT
HINT: The removal procedure for the RH side is the same as that for the LH side.

56. SEPARATE SPEED SENSOR FRONT LH Removal
57. SEPARATE SPEED SENSOR FRONT RH
HINT: The separation procedure for the RH side is the same as that for the LH side.

58. SEPARATE TIE ROD END SUB-ASSEMBLY LH Removal
59. SEPARATE TIE ROD END SUB-ASSEMBLY RH
HINT: The separation procedure for the RH side is the same as that for the LH side.

60. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH Removal
61. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH
HINT: The separation procedure for the RH side is the same as that for the LH side.

62. SEPARATE FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY LH Removal
63. SEPARATE FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY RH
HINT: The separation procedure for the RH side is the same as that for the LH side.

64. SEPARATE FRONT AXLE ASSEMBLY LH Removal
65. SEPARATE FRONT AXLE ASSEMBLY RH
HINT: The separation procedure for the RH side is the same as that for the LH side.

66. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE Removal
67. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY Removal
68. REMOVE NO. 1 OIL COOLER INLET TUBE (for Automatic Transaxle) Removal
69. REMOVE NO. 1 OIL COOLER OUTLET TUBE (for Automatic Transaxle) Removal
70. REMOVE NO. 2 OIL COOLER TUBE CLAMP (for Automatic Transaxle) Removal
71. REMOVE TRANSMISSION OIL LEVEL GAGE SUB-ASSEMBLY (for Automatic Transaxle)
72. SEPARATE TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY (for Automatic Transaxle) Removal
73. REMOVE INTAKE MANIFOLD Removal
74. REMOVE OIL LEVEL DIPSTICK
75. REMOVE OIL LEVEL GAGE GUIDE Removal
76. REMOVE GENERATOR ASSEMBLY Removal
77. REMOVE FAN BELT ADJUSTING BAR Removal
78. SEPARATE WATER INLET HOSE





(a) Loosen the clip and separate the water inlet hose.
79. SEPARATE NO. 3 WATER BY-PASS HOSE





(a) Loosen the clip and separate the No. 3 water by-pass hose.
80. REMOVE WATER INLET Removal
81. REMOVE THERMOSTAT Removal
82. REMOVE IGNITION COIL ASSEMBLY Removal
83. REMOVE RADIO SETTING CONDENSER Removal
84. REMOVE NO. 2 VENTILATION HOSE Removal
85. REMOVE AIR TUBE ASSEMBLY Removal
86. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Disassembly
87. SET NO. 1 CYLINDER TO TDC / COMPRESSION Disassembly
88. REMOVE CRANKSHAFT PULLEY Disassembly
89. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY Disassembly
90. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY Disassembly





91. REMOVE TIMING CHAIN OR BELT COVER OIL SEAL
(a) Using a screwdriver and hammer, remove the oil seal.
NOTICE: Be careful not to damage the timing chain or belt cover sub-assembly.
HINT: Tape the screwdriver tip before use.

92. REMOVE NO. 2 CHAIN VIBRATION DAMPER Disassembly
93. REMOVE CHAIN TENSIONER SLIPPER Disassembly
94. REMOVE NO. 1 CHAIN VIBRATION DAMPER Disassembly
95. REMOVE CHAIN SUB-ASSEMBLY Disassembly
96. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET Disassembly
97. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
(a) Check the lock of the camshaft timing gear.
(b) Release the lock pin.
NOTICE: Before removing the camshaft timing gear assembly, make sure that the lock pin has been released.




(1) After cleaning and degreasing the VVT oil hole on 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.
NOTICE: Be sure to cover the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.
(2) Prick a hole in the tape covering the oil hole as shown in the illustration. (Procedure A)




(3) 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.
NOTICE:
- If air leaks out, reattach the adhesive tape.
- Cover the oil hole with a shop rag or piece of cloth when applying air pressure to prevent oil from spraying.
- Do not lock the camshaft timing gear assembly. If it is locked, release the lock pin again.
HINT:
- The camshaft timing gear assembly may be turned in the advance direction without applying any force.
- If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.
(4) Remove the adhesive tape from the No. 1 camshaft bearing cap.





(c) Remove the flange bolt while holding the hexagonal portion of the camshaft, and then remove the camshaft timing gear assembly.
NOTICE:
- Before removing the camshaft timing gear, 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.

98. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY





(a) Remove the flange bolt while holding the hexagonal portion of the camshaft, and then remove the camshaft timing exhaust gear assembly.
NOTICE:
- Be sure not to remove the other 4 bolts.
- Keep the camshaft timing exhaust gear assembly horizontal while removing it from the camshaft.

99. REMOVE CAMSHAFT BEARING CAP





(a) Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.





(b) Uniformly loosen and remove the 15 bearing cap bolts in the sequence shown in the illustration.
NOTICE:
- Uniformly loosen the bolts while keeping the camshaft level.
- If the camshaft bearing cap bolts hare been loosened, reapply seal packing between the camshaft housing and cylinder head.

(c) Remove the 5 bearing caps.
HINT: Arrange the removed parts in the correct order.

(d) Remove the camshaft and No. 2 camshaft.
100. REMOVE CAMSHAFT





(a) Remove the camshaft.
101. REMOVE NO. 2 CAMSHAFT





(a) Remove the No. 2 camshaft.
102. REMOVE NO. 1 CAMSHAFT BEARING





(a) Remove the 2 No. 1 camshaft bearings.
HINT: Arrange the removed parts in the correct order.

103. REMOVE NO. 2 CAMSHAFT BEARING





(a) Remove the 2 No. 2 camshaft bearings.
HINT: Arrange the removed parts in the correct order.

104. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY





(a) Remove the 2 bolts.





(b) Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.
NOTICE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.
HINT: Tape the screwdriver tip before use.
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