Part 1

2ZR-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION

INSTALLATION

1. INSTALL NO. 1 CAMSHAFT BEARING
(a) Clean the both surfaces of the bearing.
(b) Install the 2 No. 1 camshaft bearings.






(c) Using vernier calipers, measure the distance between the bearing cap's edge and the camshaft bearing's edge.
Dimension (A - B):
0.7 mm (0.0276 in.) or less
NOTE: Position the bearing to the center of the bearing cap by measuring dimension A - B.

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






(c) Using vernier calipers, measure the distance between the bearing cap's edge and the camshaft bearing's edge.
Dimension (A):
1.05 to 1.75 mm (0.042 to 0.068 in.)
NOTE: Position the bearing to the center of the bearing cap by measuring dimension A.

3. 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.
4. 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.
5. INSTALL CAMSHAFT BEARING CAP
(a) Apply engine oil to the camshaft journals, camshaft housing and bearing caps.






(b) Check the marks and numbers on the camshaft bearing caps and place them in the 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)
6. 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 line as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal diameter:
3.5 to 4.0 mm (0.138 to 0.158 in.)

NOTE:
- Remove any oil from the contact surface.
- Install the camshaft housing sub-assembly RH within 3 minutes of applying the 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.

7. 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 (the right angle).





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






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






(f) Check that the camshaft timing gear can move to the retard angle side (the right direction) and is locked in the most retarded position.
8. 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 (the right angle).

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






(e) Tighten the flange bolt with the camshaft timing exhaust gear fixed.
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.
9. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET Reassembly

10. INSTALL NO. 1 CHAIN VIBRATION DAMPER Reassembly

11. INSTALL CHAIN SUB-ASSEMBLY Reassembly

12. INSTALL CHAIN TENSIONER SLIPPER Reassembly

13. INSTALL NO. 2 CHAIN VIBRATION DAMPER Reassembly







14. INSTALL TIMING CHAIN OR BELT COVER OIL SEAL
(a) Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.
SST: 09223-22010
(b) Apply a light coat of MP grease to the lip of the oil seal.
NOTICE:
- Keep the lip free of foreign matter.
- Do not tap on the oil seal at an angle.
- Make sure that the oil seal edge does not stick out of the timing chain cover.

15. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY Reassembly

16. INSTALL CRANKSHAFT PULLEY Reassembly

17. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Reassembly

18. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Reassembly

19. INSTALL AIR TUBE ASSEMBLY Installation

20. INSTALL NO. 2 VENTILATION HOSE Installation

21. INSTALL RADIO SETTING CONDENSER Installation

22. INSTALL IGNITION COIL ASSEMBLY Installation

23. INSTALL THERMOSTAT Installation

24. INSTALL WATER INLET Installation

25. INSTALL NO. 3 WATER BY-PASS HOSE






(a) Install the No. 3 water by-pass hose with the clip.
26. INSTALL WATER INLET HOSE






(a) Install the water inlet hose with the clip.
27. INSTALL FAN BELT ADJUSTING BAR Installation

28. INSTALL GENERATOR ASSEMBLY

29. INSTALL OIL LEVEL GAGE GUIDE Installation

30. INSTALL OIL LEVEL DIPSTICK
31. INSTALL INTAKE MANIFOLD Installation

32. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY (for Automatic Transaxle) Installation

33. INSTALL TRANSMISSION OIL LEVEL GAGE SUB-ASSEMBLY (for Automatic Transaxle)
34. INSTALL NO. 1 OIL COOLER OUTLET TUBE (for Automatic Transaxle) Installation

35. INSTALL NO. 1 OIL COOLER INLET TUBE (for Automatic Transaxle) Installation

36. INSTALL NO. 2 OIL COOLER TUBE CLAMP (for Automatic Transaxle) Installation

37. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY Installation

38. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE Installation

39. INSTALL FRONT AXLE ASSEMBLY LH Installation

40. INSTALL FRONT AXLE ASSEMBLY RH
HINT: The installation procedure for the RH side is the same as that for the LH side.

41. INSTALL FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY LH Installation

42. INSTALL FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY RH
HINT: The installation procedure for the RH side is the same as that for the LH side.

43. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation

44. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT: The installation procedure for the RH side is the same as that for the LH side.

45. INSTALL TIE ROD END SUB-ASSEMBLY LH Installation

46. INSTALL TIE ROD END SUB-ASSEMBLY RH
HINT: The installation procedure for the RH side is the same as that for the LH side.

47. INSTALL SPEED SENSOR FRONT LH Installation

48. INSTALL SPEED SENSOR FRONT RH
HINT: The installation procedure for the RH side is the same as that for the LH side.

49. INSTALL FRONT AXLE SHAFT LH NUT Installation

50. INSTALL FRONT AXLE SHAFT RH NUT
HINT: The installation procedure for the RH side is the same as that for the LH side.

51. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

52. INSTALL FRONT FLOOR BRACE CENTER Installation

53. INSTALL FRONT CONSOLE BOX

54. INSTALL REAR CONSOLE BOX ASSEMBLY

55. INSTALL CONSOLE BOX CARPET

56. INSTALL CONSOLE BOX REAR COVER

57. INSTALL CONSOLE PANEL UPPER