Vibe 2003-2005

Camshaft, Bearings & Lifters

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Inspection



  1. Inspect the camshaft journals and lobes for wear or scoring (1, 2).
  2.  
  3. Wash the cylinder head in solvent.
  4.  
  5. Inspect the cylinder head for cracks or other signs of damage.
  6.  
  7. Inspect the camshaft bearing caps for wear, cracks and scoring.
  8.  
  9. Inspect the camshaft bearing journals in the cylinder head for wear, cracks and scoring.
  10.  
  11. If excessive wear or scoring is present, or if the cylinder head is cracked, replace the cylinder head with bearing caps.
  12.  
  13. Measure the camshaft lobe height using a micrometer. The minimum measurement for the exhaust lobe height is 1.5693 inch on the No: 1 lobe and 1.5240 inch on the No: 2 lobe. The minimum measurement for the intake lobe height is 1.5925 inch on the No: 1 lobe and 1.5201 inch on the No: 2 lobe.
  14.  
  15. Replace the camshaft if any lobe is below the minimum.

    Click image to see an enlarged view

    Fig. Inspecting the camshaft lobe height using a micrometer



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    Fig. Inspecting the camshaft lobe runout using a dial indicator

  16.  
  17. Place the camshaft (1) onto V-blocks. Measure the camshaft runout using a dial indicator. The maximum runout is 0.0012 inch. If the runout exceeds specifications, replace the camshaft.
  18.  

Removal & Installation



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Right side engine under cover
     
    Cylinder head cover
     
    Suction hose sub-assembly, 2ZZ-GE engine
     
    Drive belt
     
    Power steering pump reservoir and position it aside, 1ZZ-FE engine
     

  4.  
  5. Place a jack with a wooden block under the vehicle for support, then remove the 4 bolts and 2 nuts and remove the right side engine mount.

    Click image to see an enlarged view

    Fig. With the engine supported, remove the right side engine mount-1ZZ-FE engine shown, 2ZZ-GE similar

  6.  
  7. Remove the engine wire, on 1ZZ-FE engines:
    1. Remove the 5 clamps from the brackets.
    2.  
    3. Detach the connectors.
    4.  
    5. Remove the ignition coil connectors.
    6.  
    7. Bolt and nut holding the engine wire.
    8.  

  8.  
  9. Remove or disconnect the following:

    Ignition coil assembly
     
    Positive Crankcase Ventilation (PCV) hoses from the valve cover
     
    Valve (cylinder head) cover sub-assembly
     

  10.  
  11. Set the No. 1 cylinder to Top Dead Center (TDC) of the compressor stroke as follows:
    1. Turn the crankshaft pulley, and align its groove with the -0- timing mark of the timing chain cover.
    2.  
    3. Make sure the point marks of the camshaft timing sprockets and VVT timing sprockets are in a straight line as shown. If not, turn the crankshaft 1 complete revolution (360°) and align the marks.

      Click image to see an enlarged view

      Fig. Proper timing mark alignment for TDC

    4.  

  12.  
  13. Remove the drive belt tensioner.
    WARNING
    Do not turn the crankshaft without the tensioner installed.

  14.  
  15. Make sure the No. 1 cylinder is at TDC of the compression stroke.
  16.  
  17. Matchmark the timing chain and camshaft sprockets

    Click image to see an enlarged view

    Fig. Matchmark the timing chain and cam sprockets

  18.  
  19. Remove the 2 nuts and chain tensioner.

    Click image to see an enlarged view

    Fig. Hold the camshaft with a wrench while removing the set bolt

  20.  
  21. Hold the camshafts with a wrench and loosen the camshaft set bolt.
  22.  
  23. Using several passes, gradually remove the bearing cap bolts from the No. 2 camshaft, in the proper sequence.

    Click image to see an enlarged view

    Fig. Camshaft bearing cap bolt removal sequence-1ZZ-FE engine



    Click image to see an enlarged view

    Fig. Camshaft bearing cap bolt removal sequence-2ZZ-GE engine

  24.  
  25. Remove the camshaft and timing gear as shown.

    Click image to see an enlarged view

    Fig. Carefully remove the cam and timing gear

  26.  
  27. Using several passes, gradually remove the bearing cap bolts from the other camshaft, in the proper sequence.

    Click image to see an enlarged view

    Fig. Camshaft bearing cap bolt removal sequence-1ZZ-FE engine

  28.  
  29. Remove the camshaft while holding the timing chain.
    WARNING
    Do not let anything drop down into the timing chain cover while the camshafts are removed.

  30.  
  31. Tie the timing chain with a string as shown, to prevent it from dropping down into the timing chain cover.

    Click image to see an enlarged view

    Fig. Secure the timing chain with string to prevent it from slipping down into the timing chain cover

  32.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the camshafts and related components-1ZZ-FE engine



Click image to see an enlarged view

Fig. Exploded view of the camshafts and related components-2ZZ-GE engine

  1. Position the camshaft on the cylinder head, then install the timing chain on the cam timing gear, with the painted links aligned with the marks on the timing gear.

    Click image to see an enlarged view

    Fig. Make sure the alignment marks on the timing chain and camshaft gear match up

  2.  
  3. Check the front marks and numbers and torque the camshaft cap bolts, in sequence, to 10 ft. lbs. (13 Nm) for 1ZZ-FE engine, or to 14 ft. lbs. (19 Nm) for 2ZZ-GE engines.

    Click image to see an enlarged view

    Fig. Camshaft cap bolt tightening sequence-1ZZ-FE engine



    Click image to see an enlarged view

    Fig. Camshaft cap bolt tightening sequence-2ZZ-GE engine

  4.  
  5. Put camshaft No. 2 on the cylinder head, with the painted links of the chain aligned with the mark on the timing gear.
  6.  
  7. Tighten the camshaft gear set bolt temporarily.
  8.  
  9. Check the front marks and numbers and torque the camshaft cap bolts, in sequence, to 10 ft. lbs. (13 Nm). Install the No. 1 bearing cap and tighten to 17 ft. lbs. (23 Nm).

    Click image to see an enlarged view

    Fig. Camshaft cap bolt tightening sequence-1ZZ-FE

  10.  
  11. Hold the camshaft secure with a wrench and tighten the set bolt to 40 ft. lbs. (54 Nm). Be careful not the damage the lifters.
  12.  
  13. Check to be sure the matchmarks on the timing chain and cam sprockets, and the alignment of the pulley groove with the timing mark on the cover are still aligned.
  14.  
  15. Install the chain tensioner:
    1. Make sure the O-ring is clean, then set the hook as shown.

      Click image to see an enlarged view

      Fig. Set the timing chain tensioner hook properly

    2.  
    3. Oil the tensioner, then install and tighten to 80 inch lbs. (9 Nm).
      NOTE
      When installing the tensioner, set the hook again if the hook releases the plunger.

    4.  
    5. Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook.
    6.  
    7. Turn the crankshaft clockwise and check that the slipper is pushed by the plunger. If the plunger does not spring out, press the slipper into the chain tensioner with a screwdriver so that the hook is released from the knock pin and the plunger springs out.
    8.  

  16.  
  17. Check the valve clearance and make adjustments as needed.
  18.  
  19. Install or connect the following:

    Belt tensioner. Tighten the nut to 21 ft. lbs. (29 Nm) and the bolt to 51 ft. lbs. (69 Nm).
     
    Cylinder head sub-assembly cover. Install seal packing into the locations shown and install within 3 minutes. Tighten the -A- bolts to 8 ft. lbs. (11 Nm) and the -B- bolts to 80 inch lbs. (9 Nm) for 1ZZ-FE engine and to 7 ft. lbs. (10 Nm) for 2ZZ-GE engines.

    Click image to see an enlarged view

    Fig. Seal packing installation locations



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    Fig. Cylinder head (valve) cover bolt locations-1ZZ-FE engine

     
    Ignition coil assembly. Torque the bolts to 80 inch lbs. (9 Nm).
     
    Engine wire and tighten to 80 inch lbs. (9 Nm)
     
    Right side engine mount. Tighten to 38 ft. lbs. (52 Nm).
     
    Cylinder head (valve) cover
     
    Negative battery cable
     

  20.  

 
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