Toyota 13502-22011
Camshaft

The first step to take the camshaft off the 1ZZ-FE engine requires disconnecting the negative terminal of the battery and removing the engine under cover RH. The first step involves removing the cylinder head cover No. 2 followed by the ignition coil assembly after which you should remove the cylinder head cover sub-assembly. The technician sets the No. 1 cylinder to Top Dead Center position during compression stroke. After marking the timing chain and camshaft timing gears, remove their accompanying two nuts and the chain tensioner following a rule of not spinning the crankshaft when the tensioner is absent. Loosen the camshaft timing gear set bolt by using a wrench on the camshaft with caution to prevent harming the valve lifter. The specified order requires the removal of 11 bolts while they are being uniformly loosened before extracting the 5 bearing caps together with the camshaft timing gear. The procedure for removing the camshaft includes uniformly loosening and removing the specified sequence of 8 bolts followed by removing the 4 bearing caps. The timing chain cover requires careful camshaft removal with the camshaft timing gear along with an immediate handholding of the timin chain and subsequent string tie to prevent content from entering the timing chain cover.

The process to remove the camshaft begins by taking out the engine unit plus generator and ignition coils and spark plugs and injectors and exhaust manifold through disconnecting heated oxygen sensor connectors and then discarding heated oxygen sensors before uninstalling 4 upper heat insulator bolts and 4 exhaust manifold stays bolts and the exhaust manifold with its attached gasket and 5 bolts. Next, disconnect the engine wire by detaching the heated oxygen sensor (bank 1 sensor 1) wire from the 2 wire brackets, the camshaft timing oil control valve connector, the crankshaft position sensor connector, the knock sensor connector, the oil pressure switch connector and wire, the camshaft position sensor connector, the ECT sensor connector, the throttle position sensor connector, the throttle control motor connector (SMT: 1), the accelerator position sensor connector (SMT: 2), the IAC valve connector, and the noise filter, then remove the 2 bolts and disconnect the 2 ground straps, followed by removing the 2 bolts and engine wire. Following this disconnect the PCV components by removing both PCV hoses and the PCV valve with its grommet. First disconnect the two water hoses from the throttle body and remove the two vacuum hoses from the intake manifold before you take out the four bolts and the two nuts and two wire brackets that allow for the removal of the intake manifold with throttle body assembly and its accompanying gasket. After the camshaft timing chain and timing sprocket and VVT sprocket removal process comes the removal of the camshaft timing oil control valve. To access camshaft components remove the 9 bearing caps together with the intake and exhaust camshafts after successive uniform bolt loosening of the 19 bearing cap bolts according to specified bolt sequences. The final step involves removing the cylinder head assembly after removing the water bypass pipe bolt from the cylinder head while applying a 10 mm bi-hexagon wrench for cyclic bolt loosening of the 10 cylinder head bolts in the correct order followed by removal of the 10 plate washers. Use a plastic prying tool to detach the cylinder head from the cylinder block while avoiding any surface damage to the contact areas. Remove the engine components by taking out the camshaft timing oil control valve filter as well as the camshaft position sensor and the ECT sensor.

Set the No.1 cylinder to TDC/Compression.

Install bearing cap No. 1 with a torque of 23 Nm (235 kg-cm, 17 ft-lb).

Uniformly loosen and remove the 11 bolts in the specified sequence and the 5 bearing caps, followed by the camshaft timing gear.

Tie the timing chain with a string.

Remove the cylinder head cover No.2, which involves taking out 2 screws, 3 clips, and the engine under cover.

Turn the V-ribbed belt tensioner clockwise, then remove the belt and gradually return the tensioner to its original position.

While holding the camshaft, tighten the camshaft timing gear set bolt to 54 Nm (551 kgf-cm, 40 ft. lbs.), ensuring not to damage the valve lifter, and check that the 2 point marks are aligned on the timing chain cover surface.

Turn the V-ribbed belt tensioner clockwise to loosen it, then carefully re-adjust the tensioner.

Hold the timing chain by hand and tie it with a string to prevent dropping anything inside the timing chain cover.

Remove the camshaft by uniformly loosening and removing the 8 bolts in the specified sequence and the 4 bearing caps.

Break through the tapes of the advance and retard side paths, apply air pressure to both paths, and confirm the camshaft timing gear assembly revolves in the timing advance direction.

Carefully take out the camshaft and camshaft timing gear while holding the timing chain by hand, and tie the timing chain with a string, ensuring nothing is dropped inside the timing chain cover.

Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts, then use a 10 mm bi-hexagon wrench to install and uniformly tighten the 10 cylinder head bolts and plate washers in several passes to a torque of 49 Nm (500 kgf-cm, 36 ft. lbs.).