LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2009 >> Corolla XLE, 1.8 L >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (2ZR-FE) >> Camshaft >> Installation

Engine Mechanical (2ZR-FE): Camshaft: Installation

  1. INSTALL NO. 1 CAMSHAFT BEARING 
    1. Clean 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.
    3. Using a vernier caliper, measure the distance between the bearing cap edge and the camshaft bearing edge.
      Fig 1: Measuring Distance Between Bearing Cap Edge And Camshaft Bearing Edge
      GTY193237Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Dimension (A - B)

      0.7 mm (0.0276 in.) or less

      NOTE:

      Position the bearings to the center of the bearing cap by measuring dimensions A and B.

  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 a vernier caliper, measure the distance between the bearing cap edge and the camshaft bearing edge.
      Fig 2: Measuring Distance Between Bearing Cap Edge And Camshaft Bearing Edge With Vernier Caliper
      GTY172852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Dimension (A)

      1.05 to 1.75 mm (0.0413 to 0.0689 in.)

      NOTE:

      Position the bearings to the center of the bearing cap by measuring dimension A.

  3. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Secure the hexagonal portion of the camshaft in a soft jaw vise.
    2. Check that the knock pin is installed on the camshaft.
    3. Put the camshaft timing gear and camshaft together with the knock pin and key groove misaligned, as shown in the illustration.
      Fig 3: Identifying Knock Pin & Key Groove
      GTY163714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not forcefully push in the camshaft timing gear assembly. This may cause the camshaft knock pin tip to damage the installation surface of the camshaft timing gear assembly.

    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.
      Fig 4: Turning Camshaft Timing Gear
      GTY165718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not turn the camshaft timing gear in the retard direction (the right angle).

    5. Check that there is no clearance between the camshaft timing gear and camshaft flange.
      Fig 5: Checking Clearance Between Camshaft Timing Gear And Camshaft Flange
      GTY186872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Tighten the flange bolt with the camshaft timing gear fixed in place.
      Fig 6: Tightening Flange Bolt
      GTY185877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:

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

    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 7: Checking Camshaft Timing Gear Can Move To Retard Angle Side
      GTY186034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL CAMSHAFT 
    1. Make sure that the valve rocker arm is installed as shown in the illustration.
      Fig 8: Applying Engine Oil To Lash Adjuster Tips And Valve Stem Cap Ends
      GTY146659Courtesy 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. Hold up the chain and align the matchmark and the paint mark and install the camshaft.
      Fig 9: Aligning Camshaft Matchmark And Paint Mark
      GTY179951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL NO. 2 CAMSHAFT 
    1. Make sure that the valve rocker arm is installed as shown in the illustration.
      Fig 10: Applying Engine Oil To Lash Adjuster Tips And Valve Stem Cap Ends
      GTY146659Courtesy 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.
      Fig 11: View Of No. 2 Camshaft From Camshaft Housing
      GTY182626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. 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 12: Removing/Installing Bearing Caps And Bolts In Sequence
      GTY187780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Service Bolt and Spacer (used to temporarily secure the camshaft housing) *2 Knock Pin
      *3 Paint Mark *4 Matchmark
      *a The removal order of the bolts and spacers for temporarily tightening the camshaft housing *b The installation order of the parts

      Torque: 27 N*m (275 kgf*cm, 20 ft.*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 orientation of the knock pin and matchmark on the camshaft is as shown in the illustration.

    2. Tighten the 10 bolts in the order shown in the illustration.
      Fig 13: Tightening Bolt Sequence
      GTY172392Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Check the torque of each bolt again.
  7. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. Hold the hexagonal portion of the intake camshaft with a wrench and turn it slightly counterclockwise to release the chain.
      Fig 14: Installing/Removing Camshaft Timing Exhaust Gear Assembly
      GTY179108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the bolt to the camshaft timing exhaust gear assembly.
    3. Align the paint mark with the matchmark to install the chain.
      NOTE:
      • Do not turn the intake camshaft more than necessary.
      • Do not install the camshaft timing exhaust gear to the camshaft at this time. Make sure to only install the chain to the camshaft timing exhaust gear.
    4. Put the camshaft timing exhaust gear and camshaft together by aligning the key groove and knock pin.
      Fig 15: Identifying Key Groove & Knock Pin
      GTY166598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the straight pin cannot be aligned with the pin hole, hold the hexagonal portion of the No. 2 camshaft with a wrench and turn it slightly to install the gear.
      • Do not turn the No. 2 camshaft more than necessary.
      • Do not forcefully push in the camshaft timing exhaust gear assembly. This may cause the camshaft knock pin tip to damage the installation surface of the camshaft timing exhaust gear assembly.
    5. Using SST and a wrench, hold the hexagonal portion of the No. 2 camshaft and install the camshaft timing exhaust gear assembly to the No. 2 camshaft.
      Fig 16: Holding Hexagonal Portion Of No. 2 Camshaft
      GTY167312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09249-37010 

      without SST 

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

      with SST 

      Torque: 39 N*m (397 kgf*cm, 29 ft.*lbf) 

      NOTE:
      • 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.
  8. INSTALL NO. 2 CHAIN VIBRATION DAMPER 
    1. Using SST, install the No. 2 chain vibration damper with the 2 bolts.
      Fig 17: Installing No. 2 Chain Vibration Damper
      GTY194621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09961-00950 

      without SST 

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

      with SST 

      Torque: 5.5 N*m (56 kgf*cm, 48 in.*lbf) 

      NOTE:
      • The "with SST" torque value can be obtained by using a torque wrench with a fulcrum length of 180 mm (7.09 in.) and SST of 150 mm (5.91 in.). Refer to PRECAUTION .
      • This torque value is effective when SST is parallel to the torque wrench.
  9. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY  See step  38
  10. 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 18: 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.
  11. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY  See step  42
  12. INSTALL AIR TUBE 
    1. Install the air tube assembly with the 2 bolts.
      Fig 19: Identifying Air Tube Assembly Bolts & Hoses
      GTY166465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. Connect the 4 hoses.
  13. CONNECT ENGINE WIRE 
    1. Connect the 5 connectors and install the wire harness with the 2 bolts and 5 clamps.
      Fig 20: Identifying Engine Wire Bolts, Connectors & Clamps
      GTY163265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  14. CONNECT NO. 2 VENTILATION HOSE 
    1. Connect the No. 2 ventilation hose.
      Fig 21: Locating No. 2 Ventilation Hose
      GTY164707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL RADIO SETTING CONDENSER  See step  1
  16. INSTALL IGNITION COIL ASSEMBLY  . Refer to INSTALLATION - Step 2
  17. INSPECT FOR ENGINE OIL LEAK 
  18. INSTALL NO. 2 CYLINDER HEAD COVER  See step  85
  19. INSTALL OUTER COWL TOP PANEL (for TMC Made)  . Refer to INSTALLATION - Step 13
  20. INSTALL OUTER COWL TOP PANEL (except TMC Made)  . Refer to INSTALLATION - Step 14
  21. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  . Refer to INSTALLATION - Step 2
  22. INSTALL COWL TOP VENTILATOR LOUVER LH  . Refer to INSTALLATION - Step 3
  23. INSTALL CENTER NO. 1 COWL TOP VENTILATOR LOUVER  . Refer to INSTALLATION - Step 4
  24. INSTALL HOOD TO COWL TOP SEAL  . Refer to INSTALLATION - Step 5
  25. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH  . Refer to INSTALLATION - Step 6
  26. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH  . Refer to INSTALLATION - Step 7
  27. INSTALL FRONT WIPER ARM HEAD CAP  . Refer to INSTALLATION - Step 8
  28. INSPECT IGNITION TIMING  See step  8
  29. INSPECT ENGINE IDLING SPEED  See step  9
scientia non olet · About LEMON Manuals