LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2009 >> Matrix XRS, Automatic >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 6 (Engine Mechanical (2ZR-FE)) >> Camshaft >> Installation

Section 6 (Engine Mechanical (2ZR-FE)): Camshaft: Installation

WARNING: This page is about a different variant/trim than selected.
  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 No. 1 camshaft bearings.
    3. Using a vernier caliper, measure the distance between the bearing cap edge and the camshaft bearing edge.

      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.
    Fig 1: Identifying No. 2 Camshaft Bearings
    G00514556Courtesy 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 a vernier caliper, measure the distance between the bearing cap edge and the camshaft bearing edge.

      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.
      Fig 2: Measuring Distance Between Bearing Cap Edge And Camshaft Bearing Edge
      G06008681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
      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.
      Fig 3: 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).
    5. Check that there is no clearance between the camshaft timing gear and camshaft flange.
      Fig 4: Checking No Clearance Between Camshaft Timing Gear And Camshaft Flange
      G00514544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Tighten the flange bolt with the camshaft timing gear fixed in place.

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

      NOTE: When tightening the bolts, do not allow the camshaft timing gear assembly to rotate.
      Fig 5: Identifying Flange Bolt
      G00514557Courtesy 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 6: Camshaft Timing Gear Lock Position
      G00514558Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. Make sure that the valve rocker arm is installed as shown in the illustration.
      Fig 7: 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 8: 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.
    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 9: 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 10: Removing/Installing Bearing Caps And Bolts In Sequence
      GTY187780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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, 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 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.

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

      Fig 11: Tightening Bolt Sequence
      GTY172392Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 12: 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.
      • Align the paint mark with the matchmark to install the chain.
    4. Put the camshaft timing exhaust gear and camshaft together by aligning the key groove and knock pin.
      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.
      Fig 13: Identifying Key Groove & Knock Pin
      GTY166598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

      SST: 09249-37010 

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

      with SST - Torque: 39 N*m (397 kgf*cm, 29ft*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.
      Fig 14: Holding Hexagonal Portion Of No. 2 Camshaft
      GTY167312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL NO. 2 CHAIN VIBRATION DAMPER 
    1. Using SST, install the No. 2 chain vibration damper with the 2 bolts.

      SST: 09961-00950 

      without SST - Torque: 10 N.m (102 kgf.cm, 7ft.lbf) 

      with SST - Torque: 5.5 N.m (56 kgf.cm, 48in.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.
    Fig 15: Aligning Crankshaft Pulley & Timing Chain Cover
    GTY164677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY  . Refer to REASSEMBLY .
  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 16: 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  . Refer to REASSEMBLY )
  12. INSTALL AIR TUBE 
    1. Install the air tube assembly with the 2 bolts.

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

      Fig 17: Identifying Air Tube Assembly Bolts & Hoses
      GTY166465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

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

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