Installation

2AZ-FXE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION

1. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

(a) Put the camshaft timing gear and camshaft together with the straight pin and key groove misaligned as shown in the illustration.

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(b) 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.

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NOTICE:
Be sure not to turn the camshaft timing gear to the retard direction (clockwise).

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

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(d) Tighten the flange bolt with the camshaft timing gear assembly secured in place.

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Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)

(e) Check that the camshaft timing gear assembly can move to the retard direction (clockwise) and is locked in the most retarded position.

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2. INSTALL CAMSHAFT

(a) Apply a light coat of engine oil to the journal portion of the camshaft.

(b) Install the timing chain onto the camshaft timing gear with the paint mark aligned with the timing mark on the camshaft timing gear as shown in the illustration.

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(c) Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head.

(d) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

(e) Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.

No. 1 bearing - Torque : 30 Nm (301 kgf-cm, 22 ft-lbf)

No. 3 bearing - Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

3. INSTALL NO. 2 CAMSHAFT

(a) Apply a light coat of engine oil to the journal portion of the No. 2 camshaft.

(b) Put the No. 2 camshaft timing sprocket on the cylinder head with the paint mark on the chain aligned with the timing mark on the No. 2 camshaft timing sprocket.

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(d) Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head.

(e) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

(f) Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.

No. 2 bearing - Torque : 30 Nm (301 kgf-cm, 22 ft-lbf)

No. 3 bearing - Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

(g) Using a union nut wrench, while holding the No. 2 camshaft with a wrench, tighten the camshaft timing sprocket set bolt.

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Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)

NOTICE:
* Be careful not to damage the valve lifter.
* Use the formula to calculate special torque values for situations where union nut wrench is combined with a torque wrench Service Precautions.

(h) Check that the paint marks on the chain are aligned with the timing marks on the camshaft timing gear and camshaft timing sprocket. Also, check that the crankshaft pulley groove is aligned with the timing mark "0" on the timing mark chain cover.

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4. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Reassembly

5. SET NO. 1 CYLINDER TO TDC/COMPRESSION Removal

6. CHECK VALVE CLEARANCE Adjustments

7. ADJUST VALVE CLEARANCE Adjustments

8. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Remove any old packing material from the contact surfaces.

(b) Apply seal packing to the 2 locations shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTICE:
* Remove any oil from the contact surfaces.
* Install the cylinder head cover within 3 minutes of applying seal packing.
* Do not add engine oil for at least 2 hours after installing the cylinder head cover.

(c) Install the cylinder head cover with the 8 bolts and 2 nuts.

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Bolt A - Torque : 11 Nm (112 kgf-cm, 8 ft-lbf)

Bolt B - Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)

Nut - Torque : 11 Nm (112 kgf-cm, 8 ft-lbf)

(d) Install the wire harness with the 5 bolts.

Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

(e) Connect the 2 ventilation hoses to the cylinder head cover sub-assembly.

9. INSTALL IGNITION COIL ASSEMBLY Installation

10. INSPECT FOR OIL LEAK

11. INSPECT IGNITION TIMING Engine

12. INSTALL AIR CLEANER CASE Installation

13. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY Installation

14. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation

15. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY Installation

16. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL Installation

17. INSTALL WATER GUARD PLATE RH Installation

18. INSTALL COWL BODY MOUNTING REINFORCEMENT RH Installation

19. INSTALL WINDSHIELD WIPER MOTOR AND LINK

(a) Install the windshield wiper motor and link Installation.

20. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY Installation

21. INSTALL COOL AIR INTAKE DUCT SEAL Installation

22. INSTALL REAR ENGINE UNDER COVER RH

23. INSTALL FRONT WHEEL RH

Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)