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2ZR-FE Engine Mechanical: Camshaft: Installation

  1. INSTALL NO. 1 CAMSHAFT BEARING 
    1. Clean the both surfaces of the 2 No. 1 camshaft bearings.
      NOTE: Do not apply engine oil to the bearings or the contact surfaces.
    2. Install the 2 No. 1 camshaft bearings to the No. 1 camshaft bearing cap.
    3. Using vernier calipers, measure the distance between the bearing cap's edge and the camshaft bearing's edge.

      Dimension (A - B): 0.7 mm (0.0276 in.) or less 

      NOTE: Position the bearing to the center of the bearing cap by measuring dimension A - B.
      Fig 1: Identifying Bearing Cap's Edge Dimension
      G05398865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL NO. 2 CAMSHAFT BEARING 
    1. Clean both surfaces of the 2 No. 2 camshaft bearings.
      NOTE: Do not apply engine oil to the bearings or the contact surfaces.
    2. Install the 2 No. 2 camshaft bearings.
    3. Using vernier calipers, measure the distance between the bearing cap's edge and the camshaft bearing's edge.

      Dimension (A): 1.05 to 1.75 mm (0.042 to 0.068 in.) 

      NOTE: Position the bearing to the center of the bearing cap by measuring dimension A.
      Fig 2: Identifying Bearing Cap's Edge Dimension
      G05398866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 2 CAMSHAFT 
    1. Make sure that the valve rocker arm is installed as shown in the illustration.
      Fig 3: Identifying Valve Rocker Arm
      G00514539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Clean the camshaft journals.
    3. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.
    4. Install the No. 2 camshaft to the camshaft housing.
      5. Fig 4: Identifying No. 2 Camshaft
      G05398860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL CAMSHAFT 
    1. Make sure that the valve rocker arm is installed as shown in the illustration.
      Fig 5: Identifying Valve Rocker Arm
      G00514539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Clean the camshaft journals.
    3. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.
    4. Install the camshaft to the camshaft housing.
      5. Fig 6: Identifying Camshaft
      G05398859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL CAMSHAFT BEARING CAP 
    1. Check the marks and numbers on the camshaft bearing caps, and then remove the service bolts and spacers in the order shown in the illustration. Immediately after removing the service bolts and spacers in the location for bearing caps, install the bearing caps with the bolts in the order shown in the illustration.
      Fig 7: Identifying Bearing Caps In Sequence
      G00514540Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Service Bolt and Spacer (used to temporarily secure the camshaft housing) *2 Knock Pin
      *a The removal order of the bolts and spacers for temporarily tightening the camshaft housing *b The installation order of the parts
      *c 50° - -

      Torque: 27 N*m (275 kgf*cm, 20ft*lbf) 

      NOTE: 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 remove the service bolt and spacer from one bearing cap at a time.

      HINT: make sure that the knock pin of the camshaft is positioned as shown in the illustration. 

    2. Tighten the 10 bolts in the order shown in the illustration.

      Torque: 16 N*m (163 kgf*cm, 12ft*lbf) 

      Fig 8: Locating Bolts And Tightening Sequence
      G05398870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check the torque of each bolt again.
  6. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Check that the knock pin is installed on the camshaft.
    2. Hold up the chain and align the matchmark on the camshaft timing gear assembly and the paint mark on the chain.
      Fig 9: Aligning Matchmark
      G00514541Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Put the camshaft timing gear and camshaft together with the knock pin and key groove misaligned, as shown in the illustration.
      NOTE: Do not forcefully push in the camshaft timing gear assembly. This may cause the camshaft knock pin tip t damage the installation surface for the camshaft timing gear assembly.
      Fig 10: Identifying Knock Pin And Key Groove
      G00514542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Turn the camshaft timing gear as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.
      NOTE: Do not turn the camshaft timing gear in the retard direction (the right angle).
      Fig 11: Turning Camshaft Timing Gear
      G00514543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Check that there is no clearance between the camshaft timing gear and camshaft flange.
      Fig 12: Identifying No Clearance Between Camshaft Timing Gear And Camshaft Flange
      G00514544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using SST and a wrench, hold the hexagonal portion of the camshaft and fix the camshaft timing gear assembly to the camshaft with the bolt.

      SST: 09249-37010 

      without SST - Torque: 54 N*m (551 kgf*cm, 40ft*lbf) 

      with SST - Torque: 39 N*m (398 kgf*cm, 29ft*lbf) 

      NOTE: When tightening the bolts, do not allow the camshaft timing gear assembly to rotate.

      HINT:  

      • The "with SST" torque value can be obtained by using a torque wrench with a fulcrum length of 260 mm (10.24 in.) and SST of 100 mm (3.94 in.) Refer to PRECAUTION .
      • This torque value is effective when SST is parallel to the torque wrench.

      Fig 13: Using SST To Fix Camshaft Timing Gear Assembly
      G00514545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Check that the camshaft timing gear can move to the retard angle side (the right direction) and is locked in the most retarded position.
      Fig 14: Locking Camshaft Timing Gear
      G00514546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Check that the knock pin is installed on the camshaft.
    2. Hold up the chain and align the matchmark on the camshaft timing gear assembly and the paint mark on the chain.
      Fig 15: Identifying Matchmark
      G00514547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Put the camshaft timing exhaust gear and camshaft together by aligning the key groove and straight pin.
      NOTE: Do not forcefully push in the camshaft timing exhaust gear assembly. This may cause the camshaft knock pin to damage the installation surface of the camshaft timing exhaust gear assembly.
      4. Fig 16: Identifying Key Groove And Straight Pin
      G04974660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a wrench, hold the hexagonal portion of the No. 2 camshaft and fix the camshaft timing exhaust gear assembly to the No. 2 camshaft with the bolt.

      Torque: 54 N*m (551 kgf*cm, 40 ft*lbf) 

      Fig 17: Locating Flange Bolt
      G05398880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL NO. 2 CHAIN VIBRATION DAMPER 
    1. Install the No. 2 chain vibration damper with the 2 bolts.

      Torque: 10 N*m (102 kgf*cm, 7ft*lbf) 

      Fig 18: Identifying Chain Vibration Damper
      G00514548Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY  . Refer to REASSEMBLY .
  10. INSTALL SERVICE COVER 
    1. Remove any old packing material from the contact surface.
    2. Make sure to clean and degrease the fitting surfaces of the service cover and timing chain cover so that they are free of grease, water or any contamination.
    3. Apply a continuous bead of seal packing (Diameter 5.0 mm (0.197 in.)) as shown in the illustration.
      Fig 19: Identifying Seal Packing
      GTY163020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Remove any oil from the contact surface.
      • Install the service cover within 3 minutes after applying seal packing.
      • Do not add engine oil within 2 hours after installing the service cover.
    4. Install the service cover to the timing chain cover with the 5 bolts.

      Torque: 9.1 N*m (93 kgf*cm, 81 ft.*lbf) 

  11. SET NO. 1 CYLINDER TO TDC / COMPRESSION 
    1. Turn the crankshaft pulley until its timing notch (groove) and the timing mark "0" of the timing chain cover are aligned.
      Fig 20: Aligning Crankshaft Pulley & Timing Chain Cover
      GTY164677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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.
  12. INSTALL CYLINDER HEAD COVER GASKET  . Refer to REASSEMBLY .
  13. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY  . Refer to REASSEMBLY .
  14. INSTALL AIR TUBE ASSEMBLY 
    1. Install the air tube assembly with the 2 bolts.

      Torque: 10 N.m (102 kgf.cm, 7ft.lbf) 

    2. Connect the 4 hoses.
    Fig 21: Identifying Air Tube Assembly
    G00514549Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. CONNECT ENGINE WIRE 
    1. Connect the 5 connectors and install the wire harness with the 2 bolts and 5 clamps.

      Torque: 8.4 N.m (86 kgf.cm, 74in.lbf)  

    Fig 22: Identifying Engine Wire Bolts, Connectors & Clamps
    GTY163265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. CONNECT NO. 2 VENTILATION HOSE 
    1. Connect the No. 2 ventilation hose.
    Fig 23: Locating No. 2 Ventilation Hose
    GTY164707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL RADIO SETTING CONDENSER  . Refer to INSTALLATION .
  18. INSTALL IGNITION COIL ASSEMBLY  . Refer to INSTALLATION .
  19. INSPECT FOR ENGINE OIL LEAK 
  20. INSTALL NO. 2 CYLINDER HEAD COVER  . Refer to INSTALLATION .
  21. INSTALL OUTER COWL TOP PANEL  . Refer to INSTALLATION .
  22. INSTALL FRONT AIR SHUTTER SEAL RH  . Refer to INSTALLATION .
  23. INSTALL FRONT WIPER MOTOR AND LINK  . Refer to INSTALLATION .
  24. INSTALL COWL TOP VENTILATOR LOUVER LH  . Refer to INSTALLATION .
  25. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  . Refer to INSTALLATION .
  26. INSTALL HOOD TO COWL TOP SEAL  . Refer to INSTALLATION .
  27. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH  . Refer to INSTALLATION .
  28. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH  . Refer to INSTALLATION .
  29. INSTALL FRONT WIPER ARM HEAD CAP  . Refer to INSTALLATION .
  30. INSPECT IGNITION TIMING  . Refer to ON-VEHICLE INSPECTION .
  31. INSPECT ENGINE IDLING SPEED  . Refer to ON-VEHICLE INSPECTION .
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