Installation
2ZR-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION
1. INSTALL NO. 1 CAMSHAFT BEARING
(a) Clean both surfaces of the 2 No. 1 camshaft bearings.
NOTICE:
Do not apply engine oil to the bearings or the contact surfaces.
(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
NOTICE:
Position the bearings to the center of the bearing cap by measuring dimensions A and B.
2. INSTALL NO. 2 CAMSHAFT BEARING
(a) Clean both surfaces of the 2 No. 2 camshaft bearings.
NOTICE:
Do not apply engine oil to the bearings or the contact surfaces.
(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.)
NOTICE:
Position the bearings to the center of the bearing cap by measuring dimension A.
3. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
(a) Secure the hexagonal portion of the camshaft in a soft jaw vise.
(b) Check that the knock pin is installed on the camshaft.
(c) Put the camshaft timing gear and camshaft together with the knock pin and key groove misaligned, as shown in the illustration.
NOTICE:
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.
(d) 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.
NOTICE:
Do not turn the camshaft timing gear in the retard direction (the right angle).
(e) Check that there is no clearance between the camshaft timing gear and camshaft flange.
(f) Tighten the flange bolt with the camshaft timing gear fixed in place.
Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)
NOTICE:
When tightening the bolts, do not allow the camshaft timing gear assembly to rotate.
(g) Check that the camshaft timing gear can move to the retard angle side (the right direction) and is locked in the most retarded position.
4. INSTALL CAMSHAFT
(a) Make sure that the valve rocker arm is installed as shown in the illustration.
(b) Clean the camshaft journals.
(c) Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.
(d) Hold up the chain and align the matchmark and the paint mark and install the camshaft.
5. INSTALL NO. 2 CAMSHAFT
(a) Make sure that the valve rocker arm is installed as shown in the illustration.
(b) Clean the camshaft journals.
(c) Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.
(d) Install the No. 2 camshaft to the camshaft housing.
6. INSTALL CAMSHAFT BEARING CAP
(a) 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.
Text in Illustration
Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)
NOTICE:
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.
(b) Tighten the 10 bolts in the order shown in the illustration.
Torque : 16 Nm (163 kgf-cm, 12 ft-lbf)
(c) Check the torque of each bolt again.
7. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
(a) Hold the hexagonal portion of the intake camshaft with a wrench and turn it slightly counterclockwise to release the chain.
(b) Install the bolt to the camshaft timing exhaust gear assembly.
(c) Align the paint mark with the matchmark to install the chain.
NOTICE:
* 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.
(d) Put the camshaft timing exhaust gear and camshaft together by aligning the key groove and knock pin.
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 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.
(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:
* 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.) Service Precautions.
* This torque value is effective when SST is parallel to the torque wrench.
8. 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:
* 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.) Service Precautions.
* This torque value is effective when SST is parallel to the torque wrench.
9. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Reassembly
10. SET NO. 1 CYLINDER TO TDC / COMPRESSION
(a) Turn the crankshaft pulley until its timing notch (groove) and the timing mark "0" of the timing chain cover are aligned.
(b) 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 Reassembly
12. INSTALL AIR TUBE
(a) Install the air tube assembly with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Connect the 4 hoses.
13. CONNECT ENGINE WIRE
(a) Connect the 5 connectors and install the wire harness with the 2 bolts and 5 clamps.
Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)
14. CONNECT NO. 2 VENTILATION HOSE
(a) Connect the No. 2 ventilation hose.
15. INSTALL RADIO SETTING CONDENSER Installation
16. INSTALL IGNITION COIL ASSEMBLY Installation
17. INSPECT FOR ENGINE OIL LEAK
18. INSTALL NO. 2 CYLINDER HEAD COVER Installation
19. INSTALL OUTER COWL TOP PANEL Installation
20. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation
21. INSTALL COWL TOP VENTILATOR LOUVER LH Installation
22. INSTALL COWL TOP VENTILATOR LOUVER RH Installation
23. INSTALL HOOD TO COWL TOP SEAL Installation
24. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation
25. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation
26. INSTALL FRONT WIPER ARM HEAD CAP Installation
27. INSPECT IGNITION TIMING Engine
28. INSPECT ENGINE IDLING SPEED Engine