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Installation








2ZR-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION

INSTALLATION

1. INSTALL VALVE LASH ADJUSTER ASSEMBLY Reassembly
2. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Reassembly
3. INSTALL NO. 1 CAMSHAFT BEARING
(a) Clean both surfaces of the bearings.
(b) Install the 2 No. 1 camshaft bearings.





(c) 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.

4. INSTALL NO. 2 CAMSHAFT BEARING
(a) Clean both surfaces of the bearings.
(b) Install the 2 No. 2 camshaft bearings.





(c) 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.

5. INSTALL NO. 2 CAMSHAFT
(a) Clean the camshaft journals.
(b) Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.





(c) Install the No. 2 camshaft to the camshaft housing.
6. INSTALL CAMSHAFT
(a) Clean the camshaft journals.
(b) Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.





(c) Install the camshaft to the camshaft housing.
7. INSTALL CAMSHAFT BEARING CAP
(a) Apply engine oil to the camshaft journals, camshaft housings and bearing caps.





(b) Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.
HINT: Make sure that the knock pin of the camshaft is positioned as shown in the illustration.





(c) Tighten the 10 bolts in the order shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)
8. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY





(a) Make sure that the valve rocker arm is installed as shown in the illustration.





(b) Apply seal packing in a continuous bead as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Bead diameter:
3.5 to 4.0 mm (0.138 to 0.158 in.)

NOTICE:
- Remove any oil from the contact surface.
- Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
- Do not start the engine for at least 2 hours after installing.





(c) Set the camshaft and No. 2 camshaft as shown in the illustration.
(d) Install the camshaft housing and tighten the 17 bolts in the order shown in the illustration.
Torque: 27 Nm (275 kgf-cm, 20 ft-lbf)
NOTICE:
- After installing the camshaft housing, make sure that the cam lobes are positioned as shown in the illustration.
- If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
- If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
- After installing the camshaft housing, wipe off any seal packing that seeped out from between the housing and the cylinder head.

9. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
(a) Check that the knock pin is installed on the camshaft.





(b) Put the camshaft timing gear and camshaft together with the straight 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.





(c) 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 (clockwise).





(d) Measure the clearance between the gear and the camshaft flange.
Clearance:
0.1 to 0.4 mm (0.004 to 0.016 in.)





(e) Tighten the flange bolt with the camshaft timing gear secured in place.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)





(f) Check that the camshaft timing gear can move in the retard direction (clockwise) and is locked in the most retarded position.
10. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
(a) Check that the knock pin is installed on the camshaft.





(b) Put the camshaft timing exhaust gear and camshaft together by aligning the key groove and straight pin.
(c) Lightly press the gear against the camshaft, and turn the gear. Push further at the position where the pin enters the groove.
NOTE: Be sure not to turn the camshaft timing exhaust gear in the retard direction (clockwise).

(d) Check that there is no clearance between the gear and the camshaft flange.





(e) Tighten the flange bolt with the camshaft timing exhaust gear secured.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)
(f) Check the camshaft timing exhaust gear lock.
(1) Make sure that the camshaft timing exhaust gear is locked.
11. INSTALL NO. 1 CHAIN VIBRATION DAMPER Installation
12. INSTALL NO. 2 CHAIN VIBRATION DAMPER Installation
13. INSTALL CHAIN SUB-ASSEMBLY Installation
14. INSTALL CHAIN TENSIONER SLIPPER Installation
15. INSTALL TIMING CHAIN COVER OIL SEAL Reassembly
16. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Installation
17. INSTALL CRANKSHAFT PULLEY Installation
18. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Reassembly
19. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Reassembly
20. INSTALL RADIO SETTING CONDENSER Installation
21. INSTALL THERMOSTAT Installation
22. INSTALL INLET WATER Installation
23. INSTALL INLET WATER HOSE Installation
24. INSTALL WATER BY-PASS HOSE Installation
25. INSTALL NO. 1 WATER BY-PASS PIPE Installation
26. CONNECT NO. 3 WATER BY-PASS HOSE Installation
27. INSTALL VENTILATION HOSE Installation
28. INSPECT EXHAUST MANIFOLD Engine Unit
29. INSTALL EXHAUST MANIFOLD Installation
30. INSTALL MANIFOLD STAY Installation
31. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Installation
32. INSTALL OIL LEVEL DIPSTICK SUB-ASSEMBLY Installation
33. INSTALL IGNITION COIL ASSEMBLY Installation
34. INSTALL FUEL INJECTOR ASSEMBLY Installation
35. INSTALL NO. 1 DELIVERY PIPE SPACER Installation
36. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY Installation
37. INSTALL FUEL TUBE SUB-ASSEMBLY Installation
38. INSTALL INTAKE MANIFOLD Installation
39. REMOVE ENGINE STAND Installation
40. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
HINT: Installation.
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