Installation

2ZR-FE ENGINE MECHANICAL: TIMING GEAR: INSTALLATION

INSTALLATION

1. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY





(a) Raise the chain.
(b) Hold the hexagonal portion of the intake camshaft with a wrench and turn it slightly counterclockwise to release the chain.
(c) Align the paint mark with the matchmark to install the chain.
NOTE: Do not turn the intake camshaft more than necessary.





(d) Align the straight pin on the No. 2 camshaft with the pin hole in the camshaft timing exhaust gear assembly and install the camshaft timing exhaust gear assembly to the No. 2 camshaft.

NOTICE:
- 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 forcibly push on the tip of the straight pin with the camshaft timing exhaust gear assembly.





(e) 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 Nm (551 kgf-cm, 40 ft-lbf)
with SST - Torque: 39 Nm (397 kgf-cm, 29 ft-lbf)

NOTICE:
- This 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.) Service Precautions.
- This torque value is effective when SST is parallel to the torque wrench.

2. INSTALL NO. 2 CHAIN VIBRATION DAMPER





(a) Using SST, install the No. 2 chain vibration damper with the 2 bolts.
SST: 09961-00950
without SST - Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
with SST - Torque: 5.5 Nm (56 kgf-cm, 48 in-lbf)

NOTICE:
- This 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.) Service Precautions.
- This torque value is effective when SST is parallel to the torque wrench.

3. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Reassembly
4. SET NO. 1 CYLINDER TO TDC/COMPRESSION





(a) Turn the crankshaft clockwise 360° to set the No. 1 cylinder to TDC/compression and align the matchmark (cutout) with the "0" mark on the timing chain (belt) cover.
(b) Check that the matchmark on each camshaft timing gear is positioned as shown in the illustration.
5. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Reassembly
6. INSTALL IGNITION COIL ASSEMBLY Installation
7. INSTALL RADIO SETTING CONDENSER Installation
8. INSTALL WIRE HARNESS





(a) Install the air tube with the 2 bolts (*2).
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Connect the 9 connectors and install the wire harness with the 2 bolts (*1) and 2 clamps.
Torque: 8.4 Nm (86 kgf-cm, 74 in-lbf)
9. INSTALL NO. 2 VENTILATION HOSE
10. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY Installation
11. CONNECT UNION TO CONNECTOR TUBE HOSE Installation
12. INSTALL NO. 2 CYLINDER HEAD COVER Installation