Removal

2ZR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL

1. REMOVE FRONT WIPER ARM HEAD CAP Removal

2. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH Removal

3. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH Removal

4. REMOVE HOOD TO COWL TOP SEAL Removal

5. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Removal

6. REMOVE COWL TOP VENTILATOR LOUVER LH Removal

7. REMOVE FRONT WIPER MOTOR AND LINK Removal

8. REMOVE FRONT AIR SHUTTER SEAL RH Removal

9. REMOVE OUTER COWL TOP PANEL Removal

10. REMOVE NO. 2 CYLINDER HEAD COVER Removal

11. REMOVE IGNITION COIL ASSEMBLY Removal

12. REMOVE RADIO SETTING CONDENSER Removal

13. DISCONNECT NO. 2 VENTILATION HOSE

(a) Disconnect the No. 2 ventilation hose.





14. DISCONNECT ENGINE WIRE

(a) Remove the 2 bolts, 5 connectors, 5 clamps and disconnect the engine wire.





15. REMOVE AIR TUBE ASSEMBLY

(a) Remove the 2 bolts, 4 hoses and air tube assembly.





16. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Disassembly

17. REMOVE CYLINDER HEAD COVER GASKET Disassembly

18. SET NO. 1 CYLINDER TO TDC / COMPRESSION

(a) Turn the crankshaft pulley until its timing notch (groove) and the timing mark "0" of the timing chain cover are aligned.





(b) Check that each matchmark of the camshaft timing gear and camshaft timing exhaust gear are aligned with each matchmark located as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration.

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





19. REMOVE SERVICE COVER

(a) Remove the 5 bolts and service cover.





(b) Using a screwdriver with its tip taped, pry at the areas shown in the illustration and remove the service cover.





NOTICE:
Do not damage the service cover or the contact surfaces of the timing chain cover.

20. REMOVE NO. 2 CHAIN VIBRATION DAMPER

(a) Remove the 2 bolts and No. 2 chain vibration damper from the camshaft bearing cap.





21. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY Disassembly

22. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

(a) While holding the hexagonal portion of the camshaft with a wrench, remove the camshaft timing exhaust gear bolt.





NOTICE:
Be sure not to remove the other 4 bolts. If any of them is removed, replace the camshaft timing exhaust gear assembly.

(b) Hold the hexagonal portion of the intake camshaft with a wrench and turn it slightly counterclockwise to release the chain.

NOTICE:
Do not turn the intake camshaft more than necessary.

HINT
Be sure to loosen the chain because the camshaft timing exhaust gear assembly cannot be removed with the chain tensioned.

(c) Remove the camshaft timing exhaust gear assembly.

NOTICE:
Keep the camshaft timing exhaust gear assembly horizontal while removing it from the camshaft.

23. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

(a) Temporarily install the camshaft timing exhaust gear assembly.





(1) Align the knock pin on the No. 2 camshaft with the pin hole in the camshaft timing exhaust gear assembly and temporarily install the camshaft timing exhaust gear assembly to the No. 2 camshaft with the bolt.

NOTICE:
* Do not install the chain onto the gear at this step.
* Do not allow the chain to interfere with the gear when installing the gear assembly.

(b) Inspect the camshaft timing exhaust gear lock.

(1) Check that the camshaft timing exhaust gear is locked.

(c) Inspect camshaft timing exhaust gear operation.





(1) After cleaning and degreasing the exhaust side VVT oil hole on 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 seal the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

(2) Make a hole in the adhesive tape covering the oil hole as shown in the illustration. (Procedure B)

(3) Apply approximately 200 kPa (2.0 kgf/cm2, 28 psi.) of air pressure to the hole made in procedure B to release the lock pin.





NOTICE:
* If air leaks out, reattach the adhesive tape.
* Cover the oil hole with a piece of cloth when applying air pressure to prevent oil from spraying.

(4) Using a screwdriver with its tip taped, forcibly turn the camshaft timing exhaust gear in the retard direction (clockwise).

NOTICE:
* Be sure to keep the camshaft timing exhaust gear in the retard direction. If the gear is released, it will return to the advanced position automatically due to the force from the spring.
* Do not damage the camshaft timing exhaust gear.

HINT
Depending on the air pressure applied, the camshaft timing exhaust gear may turn in the retard direction without assistance by hand.

(5) Using a screwdriver with its tip taped, turn the camshaft timing exhaust gear within its movable range (20°) 2 or 3 times without turning it to the most advanced position. Check that the camshaft timing gear turns smoothly.





(6) Lock the camshaft timing exhaust gear.

NOTICE:
Check that the camshaft timing exhaust gear assembly locks at the most advanced position (the most advanced position of its movable range) and cannot be rotated any further.

(7) Remove the adhesive tape from the No. 1 camshaft bearing cap.

(d) Remove the camshaft timing exhaust gear assembly.

(1) Remove the temporarily installed camshaft timing exhaust gear assembly.

24. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

(a) Inspect the camshaft timing gear lock.

(1) Check that the camshaft timing gear is locked.

(b) Inspect camshaft timing gear operation.





(1) After cleaning and degreasing the intake side VVT oil hole on 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.

CAUTION:
Be sure to seal the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

(2) Make a hole in the adhesive 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 made in procedure A to release the lock pin.





NOTICE:
* If air leaks out, reattach the adhesive tape.
* Cover the oil hole with a piece of cloth when applying air pressure to prevent oil from spraying.

(4) Forcibly turn the camshaft timing gear in the advance direction (counterclockwise).

HINT
Depending on the air pressure applied, the camshaft timing gear may turn in the advance direction without assistance by hand.

(5) Turn the camshaft timing gear within its movable range (27.5°) 2 or 3 times without turning it to the most retarded position. Check that the camshaft timing gear turns smoothly.





NOTICE:
* Do not lock the camshaft timing gear assembly.
* If camshaft timing gear assembly is locked, release the lock pin again.

(6) Remove the adhesive tape from the No. 1 camshaft bearing cap.

25. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

(a) While holding the hexagonal portion of the camshaft with a wrench, remove the camshaft timing gear assembly bolt with SST.





SST : 09249-37010

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.
* If the camshaft timing gear assembly is to be reused, be sure to use it with the lock pin released.

(b) Release the chain and remove the camshaft timing gear assembly

NOTICE:
Keep the camshaft timing gear assembly horizontal while removing it from the camshaft.

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





26. REMOVE CAMSHAFT BEARING CAP

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





NOTICE:
Be sure not to loosen the other 15 bearing cap bolts in this step.

HINT
Arrange the removed parts in the correct order.

(b) Remove the 15 bolts and bearing caps in the order shown in the illustration. Immediately after removing bearing caps, install service bolts and spacers in the order shown in the illustration.





Text in Illustration





Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)

NOTICE:
* If the bolts are loosened all at once, FIPG on the camshaft housing and cylinder head may peel off, resulting in oil oozing. Therefore, be sure to install the service bolts and spacers to one bearing cap at a time.
* Do not install the bearing caps when installing the service bolts and spacers.

HINT
* Arrange the removed parts in the correct order.
* Part number for the service bolts used to temporarily secure the camshaft housing: 91551- G0875 (15 bolts)
* Part number for the service spacers used to temporarily secure the camshaft housing: 90387- 12048 (15 spacers)

27. REMOVE CAMSHAFT

(a) Remove the camshaft from the camshaft housing.





28. REMOVE NO. 2 CAMSHAFT

(a) Remove the No. 2 camshaft from the camshaft housing.





29. REMOVE NO. 1 CAMSHAFT BEARING

(a) Remove the 2 No. 1 camshaft bearings from the No. 1 camshaft bearing cap.





HINT
Arrange the removed parts in the correct order.

30. REMOVE NO. 2 CAMSHAFT BEARING

(a) Remove the 2 No. 2 camshaft bearings.





HINT
Arrange the removed parts in the correct order.