engine mechanical camshaft (rh bank) (2gr ......g40488 hold turn a95155 a96452 g40318 g42799 g40320...

1424L−01

G40467

G41565

−ENGINE MECHANICAL CAMSHAFT (RH BANK) (2GR−FE)14−157

3026Author�: Date�:

2005 AVALON REPAIR MANUAL (RM1169U)

REPLACEMENT1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (SEE PAGE 14−21)2. REMOVE ENGINE WIRE3. REMOVE FRONT FRAME ASSY (SEE PAGE 14−21)4. REMOVE STARTER ASSY (SEE PAGE 19−9)5. REMOVE AUTOMATIC TRANSAXLE ASSY (SEE PAGE 40−8)6. REMOVE OIL LEVEL GAUGE GUIDE SUB−ASSY (SEE PAGE 14−21)7. REMOVE EXHAUST MANIFOLD SUB−ASSY RH (SEE PAGE 14−21)8. REMOVE EXHAUST MANIFOLD SUB−ASSY LH (SEE PAGE 14−21)9. REMOVE DRIVE PLATE & RING GEAR SUB−ASSY (SEE PAGE 14−208)10. FIX ENGINE ASSY11. REMOVE IDLER PULLEY SUB−ASSY NO.212. REMOVE ENGINE MOUNTING BRACKET RH (SEE PAGE 14−21)13. REMOVE WATER PUMP PULLEY (SEE PAGE 16−10)14. REMOVE V−RIBBED BELT TENSIONER ASSY (SEE PAGE 14−21)15. REMOVE TIMING GEAR COVER NO.216. REMOVE ENGINE MOUNTING STAY NO.2 RH (SEE PAGE 14−21)17. REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 LH (SEE PAGE 14−21)18. REMOVE WATER INLET HOUSING (SEE PAGE 16−10)19. REMOVE CRANKSHAFT PULLEY (SEE PAGE 14−142)20. REMOVE OIL PAN SUB−ASSY NO.2 (SEE PAGE 14−142)21. REMOVE OIL STRAINER SUB−ASSY (SEE PAGE 14−142)22. REMOVE OIL PAN SUB−ASSY (SEE PAGE 14−142)23. REMOVE INTAKE AIR SURGE TANK (SEE PAGE 11−15)24. REMOVE IGNITION COIL ASSY

25. REMOVE OIL PIPE NO.1(a) Remove the 2 oil pipe unions, and oil pipe No.1.(b) Remove the oil control valve filter LH and gaskets.

26. REMOVE OIL PIPE NO.2(a) Remove the bolt.(b) Remove the 2 oil pipe unions, and oil pipe No.2.(c) Remove the oil control valve filter RH and gaskets.

G41575

G41574

G40487

Push

14−158−ENGINE MECHANICAL CAMSHAFT (RH BANK) (2GR−FE)



27. REMOVE CYLINDER HEAD COVER SUB−ASSY(a) Remove the 12 bolts, head cover and gasket.HINT:Make sure the removed parts are returned to the same placesthey were removed from.

28. REMOVE CYLINDER HEAD COVER SUB−ASSY LH(a) Remove the 12 bolts, head cover and gasket.HINT:Make sure the removed parts are returned to the same placesthey were removed from.

29. REMOVE TIMING CHAIN COVER SUB−ASSY (SEE PAGE 17−7)30. REMOVE TIMING CHAIN COVER OIL SEAL (SEE PAGE 17−7)31. SET NO. 1 CYLINDER TO TDC/COMPRESSION (SEE PAGE 14−142)32. REMOVE CHAIN TENSIONER ASSY NO.1 (SEE PAGE 14−142)33. REMOVE CHAIN SUB−ASSY (SEE PAGE 14−142)

34. REMOVE CAMSHAFT TIMING GEARS AND NO.2CHAIN (RH BANK)

NOTICE:As the thrust clearance of the camshaft is small, the cam-shaft must be kept level while it is being removed. If thecamshaft is not kept level, the portion of the cylinder headwhich receives the shaft thrust may crack or be damaged,causing the camshaft to be seized or to be broken. To avoidthis, the following steps should be carried out.

(a) While raising the chain tensioner No.2, insert a pin of φ1.0mm (0.039 in.) into the hole to fix it.

G40488

TurnHold

A95155 A96452

G40318

G42799

G40320 G43113

45�

Knock Pin

Front View




(b) Hold each hexagonal portion of the camshaft and No.2camshaft with a wrench, and remove the camshaft timinggear set bolt.

NOTICE:� Be careful not to damage the cylinder head with the

wrench.� Do not disassemble the camshaft timing gear assem-

bly.(c) Separate the camshaft timing gears with the No.2 chain

sub−assy.35. REMOVE CHAIN TENSIONER ASSY NO.2(a) Remove the chain tensioner No.2 and bolt.36. REMOVE CAMSHAFTSNOTICE:As the thrust clearance of the camshaft is small, the cam-shaft must be kept level while it is being removed. If thecamshaft is not kept level, the portion of the cylinder headwhich receives the shaft thrust may crack or be damaged,causing the camshaft to be seized or to be broken. To avoidthis, the following steps should be carried out.(a) Remove the 3 gaskets.

(b) Make sure that the knock pin of the camshaft is positionedas shown in the illustration.

G40319

86 7

1 432

5

G40320

8

6

71

4

3

2

9

10

12

115

Protective TapeG40489

Protective Tape

G40913

Key Groove

Straight Pin




(c) Uniformly loosen and remove the 8 bearing cap bolts inthe sequence shown in the illustration.

(d) Using several steps, loosen and remove the 12 bearingcap bolts in the sequence as shown in the illustration.

(e) Remove the camshaft bearing caps, then remove thecamshafts.

NOTICE:� Uniformly loosen the bolts while keeping the cam-

shaft level.� Do not pry the camshaft with a tool by applying exces-

sive force to it.� Do not damage the intake and exhaust parts on the

cylinder head side.HINT:Make sure the removed parts are returned to the same placesthey were removed from.

37. REMOVE CAMSHAFT HOUSING SUB−ASSY RH(a) Remove the camshaft housing by prying between the cyl-

inder head and camshaft housing with a screwdriver.NOTICE:Be careful not to damage the contact surfaces of the cylin-der head and camshaft housing.HINT:Tape the screwdriver tip before use.

38. INSTALL CAMSHAFT TIMING GEAR(a) Put the camshaft timing gear and camshaft together by

aligning the key groove and straight pin.(b) Lightly press the gear against the camshaft, and turn the

gear. Push further to the position where the pin enters thegroove.

CAUTION:Be sure not to turn the camshaft timing gear in the retarddirection.

G40914

AdvanceSide Path

Retard Side Path

Open

Open

Close

Close

Vinyl Tape Rubber

G40915

AdvanceSide Path

Retard Side Path

G40916

AdvanceSide Path

Retard Side Path

HoldPressure

Decompress




(c) Check that there is no clearance between the gear’sfringe and the camshaft.

(d) Tighten the fringe bolt with the camshaft timing gear fixed.Torque: 100 N⋅m (1,020 kgf⋅cm, 74 ft⋅lbf)

(e) Check that the camshaft timing gear assembly can movein the retard direction and is locked at the most retardedposition.

39. INSPECT CAMSHAFT TIMING GEAR ASSY(a) Check the lock of the camshaft timing gear.

(1) Clamp the camshaft in a vise, and confirm that thecamshaft timing gear is locked.

NOTICE:Be careful not to damage the camshaft.(b) Release the lock pin.

(1) Cover the 4 oil paths of the cam journal with vinyltape as shown in the illustration.

HINT:2 advance side paths are provided in the groove of the cam-shaft. Plug one of the paths with a rubber piece.

(2) Break through the tape of the advance side pathand the retard side path on the opposite side to thehole of the advance side path, as shown in the il-lustration.

(3) Apply approximately 200 kPa (2.0 kgf/cm2, 28 psi)of air pressure to the two broken paths.

CAUTION:Cover the paths with a shop rag or piece of cloth when ap-plying pressure to keep oil from splashing.

(4) Check that the camshaft timing gear revolves in theadvance direction when reducing the air pressureapplied to the retard side path.

OK: Gear rotates in the advance direction.HINT:This operation releases the lock pin for the most retarded posi-tion.

A94638 G41166

Advance Side Path

Retard Side Path

Open

Close

Rubber

Open

Close

Vinyl Tape




(5) When the camshaft timing gear reaches the mostadvanced position, release the air pressure fromthe retard side path and advance side path, in thisorder.

NOTICE:Do not release the air pressure from the advance side pathfirst. The gear may abruptly shift in the retard direction andbreak the lock pin.(c) Check for smooth rotation.

(1) Rotate the camshaft timing gear within its movablerange several times, but do not turn it to the most re-tarded position. Check that the gear rotatessmoothly.

OK: Gear rotates smoothly in the advance direction withinits movable range (about 21�).

CAUTION:Do not use air pressure to perform the smooth operationcheck.(d) Check the lock in the most retarded position.

(1) Confirm that the camshaft timing gear is locked atthe most retarded position.

40. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSYLH

(a) Check the lock of the camshaft timing gear.(1) Clamp the camshaft in a vise, and confirm that the

camshaft timing gear is locked.NOTICE:Be careful not to damage the camshaft.(b) Release the lock pin.

(1) Cover the 4 oil paths of the cam journal with vinyltape as shown in the illustration.

HINT:2 advance side paths are provided in the groove of the cam-shaft. Plug one of the paths with a rubber piece.

(2) Break through the tape of the advance side pathand the retard side path on the opposite side to thehole of the advance side path, as shown in the il-lustration.

G40918

AdvanceSide Path

Retard Side Path

G40919

AdvanceSide Path

Retard Side Path

HoldPressure

Decompress




(3) Apply approximately 200 kPa (2.0 kgf/cm2, 28 psi)of air pressure to the two broken paths.

CAUTION:Cover the paths with a shop rag or piece of cloth when ap-plying pressure to keep oil from splashing.

(4) Check that the camshaft timing gear revolves in theadvance direction when reducing the air pressureapplied to the retard side path.

OK: Gear rotates in the advance direction.HINT:This operation releases the lock pin for the most retarded posi-tion.

(5) When the camshaft timing gear reaches the mostadvanced position, release the air pressure fromthe retard side path and advance side path, in thisorder.

NOTICE:Do not release the air pressure from the advance side pathfirst. The gear may abruptly shift in the retard direction andbreak the lock pin.(c) Check for smooth rotation.

(1) Rotate the camshaft timing gear within its movablerange several times, but do not turn it to the most re-tarded position. Check that the gear rotatessmoothly.

OK: Gear rotates smoothly in the advance direction withinits movable range (about 18.5�).

CAUTION:Do not use air pressure to perform the smooth operationcheck.(d) Check the lock in the most retarded position.

(1) Confirm that the camshaft timing gear is locked atthe most retarded position.

A95160

A95162 G40921

Straight PinDo not remove

Do not remove

Do not removeStraight Pin

Do not remove

Fringe Bolt

Intake Side:

Exhaust Side:

G35211

Stem EndCap

INCORRECTCORRECT

RockerArm

Lash Adjuster

G40506

G40507

2

3

48

7

6

51




41. REMOVE CAMSHAFT TIMING GEAR(a) Remove the fringe bolt and camshaft timing gear.NOTICE:� Be sure not to remove the other bolts.� If planning to reuse the gear, be sure to release the

straight pin lock before installing the gear.42. INSTALL CAMSHAFTSNOTICE:As the thrust clearance of the camshaft is small, the cam-shaft must be kept level while it is being installed. If thecamshaft is not kept level, the portion of the cylinder headwhich receives the shaft thrust may crack or be damaged,causing the camshaft to be seized or to be broken. To avoidthis, the following steps should be carried out.(a) Apply clean engine oil to the camshaft’s cam portion and

the cylinder head journals.

(b) Install the camshaft and No.2 camshaft to the camshafthousing sub−assy.

NOTICE:Before and after setting the camshaft and No.2 camshaft,check that the rocker arm is firmly set to the lash adjuster.

(c) Apply engine oil to the camshaft journal, camshaft hous-ing and bearing cap.

(d) Install the camshaft and No.2 camshaft to the camshafthousing RH.

(e) Make sure of the marks and numbers on the camshaftbearing caps an place them in each proper position anddirection.

(f) Using several steps, install and temporarily tighten the 8bearing cap bolts uniformly in the sequence as shown inthe illustration.Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf)

G40508: Seal Packing

3.5 to 4.5 (0.138 to 0.177)

mm (in.)

G40320 G40509Knock Pin

8

6

7 14

3

25

9

45�

10

11

12

Front View

G40319

8 67

14 3 2

5

G40318




43. INSTALL CAMSHAFT HOUSING SUB−ASSY RH(a) Apply seal packing in a continuous bead as shown in the

illustration.Seal packing: Part No. 08826−00080 or equivalentSeal diameter: 3.5 to 4.5 mm (0.138 to 0.177 in.)

NOTICE:� Remove any oil from the contact surface.� Install the camshaft housing sub−assy RH within 3

minutes and tighten the bolts within 15 minutes afterapplying seal packing.

� Do not start the engine for at least 2 hours after instal-lation.

(b) Install the camshaft housing RH, and tighten the 12 boltsin the order shown in the illustration.Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf)

NOTICE:Make sure that the knock pin of the camshaft is positionedas shown in the illustration before installing the camshafthousing RH.

(c) Using several steps, tighten the 8 bearing cap bolts uni-formly in the sequence as shown in the illustration.Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf)

NOTICE:Remove all excess seal packing after installing the bearingcap bolts.

(d) Install the 3 new gaskets to the camshaft bearing cap.

A95155

G40923

Timing Marks

Mark Links

G40488

Hold Turn




44. INSTALL CHAIN TENSIONER ASSY NO.2(a) Install the chain tensioner No.2 with the bolt.

Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf)(b) While compressing the tensioner, insert a pin of φ1.0 mm

(0.039 in.) into the hole to fix it.45. INSTALL CAMSHAFT TIMING GEARS AND NO.2

CHAIN (RH BANK)NOTICE:As the thrust clearance of the camshaft is small, the cam-shaft must be kept level while it is being installed. If thecamshaft is not kept level, the portion of the cylinder headwhich receives the shaft thrust may crack or be damaged,causing the camshaft to be seized or to be damaged. Toavoid this, the following steps should be carried out.

(a) Align the mark links (yellow) with the timing marks of thecamshaft timing gears as shown in the illustration.

(b) Apply a small amount of engine oil to the bolt threads andbolt−seating surface.

(c) Align the knock pin of the camshaft with the pin hole of thecamshaft timing gear. Install the camshaft timing gear andcamshaft timing exhaust gear RH with the No.2 chaininstalled.

NOTICE:Do not push the camshaft timing gear assembly to the cam-shaft forcibly when installing it.

(d) Hold the hexagonal portion of the camshaft with awrench, and tighten the 2 bolts.Torque: 100 N⋅m (1,020 kgf⋅cm, 74 ft⋅lbf)

(e) Remove the pin from the tensioner.

46. INSTALL CHAIN SUB−ASSY (SEE PAGE 14−142)47. INSTALL TIMING CHAIN COVER OIL SEAL (SEE PAGE 17−7)

SST 09316−60011 (09316−00011)48. INSTALL TIMING CHAIN COVER SUB−ASSY (SEE PAGE 17−7)49. INSTALL WATER INLET HOUSING (SEE PAGE 16−10)50. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 LH (SEE PAGE 14−21)NOTICE:Install engine mounting bracket front No.1 LH within 15 minutes after apply FIPG to timing chain cov-er.


G41575

A

13

9

3

6

1 and 11

4

12

8

7

10

25


G41574A

9

3

6

1 and 10

4

11 and 14

87

10

2

5

12 13




51. INSTALL CYLINDER HEAD COVER SUB−ASSY(a) Remove any old packing (FIPG) material and be careful

not to drop any oil on the contact surfaces of the cylinderhead, timing chain cover and cylinder head cover.

(b) Apply a continuous bead of seal packing to the cylinderhead and timing chain cover as shown in the illustration.Seal packing: Part No. 08826−00080 or equivalent

NOTICE:� Remove any oil from the contact surface.� Install the crankcase within 3 minutes after applying

seal packing.� Do not start the engine for at least 2 hours after instal-

lation.(c) Install the seal washers to the bolts.(d) Install the head cover with the 12 bolts.

Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) for bolt A10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) for bolts except A

52. INSTALL CYLINDER HEAD COVER SUB−ASSY LH(a) Remove any old packing (FIPG) material and be careful

not to drop any oil on the contact surfaces of the cylinderhead, timing chain cover and cylinder head cover.

(b) Apply a continuous bead of seal packing to the cylinderhead and timing chain cover as shown in the illustration.Seal packing: Part No. 08826−00080 or equivalent

NOTICE:� Remove any oil from the contact surface.� Install the crankcase within 3 minutes after applying

seal packing.� Do not start the engine for at least 2 hours after instal-

lation.(c) Install the seal washers to the bolts.(d) Install the head cover with the 12 bolts.

Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) for bolt A10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) for bolts except A

G40467

G41565

(A)




53. INSTALL OIL PIPE NO.2(a) Make sure that there is no foreign matter on the mesh of

the oil control valve filter RH.(b) Install the oil control valve filter RH to the oil pipe union.

Install new gaskets and temporarily install oil pipe No.2(on the head cover side).

NOTICE:Remove any oil from the contact surface.(c) Install a new gasket and temporarily install oil pipe No.2

(on the cylinder head side) with the oil check valve bolt.NOTICE:Remove any oil from the contact surface.(d) Tighten the oil pipe union (on the head cover side).

Torque: 65 N⋅m (662 kgf⋅cm, 48 ft⋅lbf)(e) Tighten the oil pipe union (on the cylinder head side).

Torque: 65 N⋅m (662 kgf⋅cm, 48 ft⋅lbf)

54. INSTALL OIL PIPE NO.1(a) Make sure that there is no foreign matter on the mesh of

the oil control valve filter LH.(b) Install the oil control valve filter LH to the oil pipe union.

Install new gaskets and temporarily install oil pipe No.1(on the head cover side).

NOTICE:Remove any oil from the contact surface.(c) Install a new gasket and temporarily install oil pipe No.1

(on the cylinder head side) with the oil check valve bolt.NOTICE:Remove any oil from the contact surface.(d) Install the bolt (A) to the cylinder head.

Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf)(e) Tighten the oil pipe union (on the head cover side).

Torque: 65 N⋅m (662 kgf⋅cm, 48 ft⋅lbf)(f) Tighten the oil pipe union (on the cylinder head side).

Torque: 65 N⋅m (662 kgf⋅cm, 48 ft⋅lbf)55. INSTALL IGNITION COIL ASSY

Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf)56. INSTALL INTAKE AIR SURGE TANK (SEE PAGE 11−15)57. INSTALL OIL PAN SUB−ASSY (SEE PAGE 14−142)58. INSTALL OIL STRAINER SUB−ASSY (SEE PAGE 14−142)59. INSTALL OIL PAN SUB−ASSY NO.2 (SEE PAGE 14−142)60. INSTALL CRANKSHAFT PULLEY (SEE PAGE 14−142)61. INSTALL ENGINE MOUNTING STAY NO.2 RH (SEE PAGE 14−21)62. INSTALL TIMING GEAR COVER NO.263. INSTALL WATER PUMP PULLEY (SEE PAGE 16−10)64. INSTALL V−RIBBED BELT TENSIONER ASSY (SEE PAGE 14−21)65. INSTALL ENGINE MOUNTING BRACKET RH (SEE PAGE 14−21)




66. INSTALL IDLER PULLEY SUB−ASSY NO.2Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf)

67. REMOVE ENGINE ASSY68. INSTALL DRIVE PLATE & RING GEAR SUB−ASSY (SEE PAGE 14−208)69. INSTALL EXHAUST MANIFOLD SUB−ASSY LH (SEE PAGE 14−21)70. INSTALL EXHAUST MANIFOLD SUB−ASSY RH (SEE PAGE 14−21)71. INSTALL OIL LEVEL GAUGE GUIDE SUB−ASSY (SEE PAGE 14−21)72. INSTALL AUTOMATIC TRANSAXLE ASSY (SEE PAGE 40−8)73. INSTALL STARTER ASSY (SEE PAGE 19−9)74. INSTALL FRONT FRAME ASSY (SEE PAGE 14−21)75. INSTALL ENGINE WIRE76. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (SEE PAGE 14−21)

engine mechanical camshaft (rh bank) (2gr ......g40488 hold turn a95155 a96452 g40318 g42799 g40320...

Documents