Installation

2AR-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION

1. INSTALL NO. 2 CAMSHAFT BEARING Reassembly

2. INSTALL NO. 1 CAMSHAFT BEARING Reassembly

3. INSTALL OIL CONTROL VALVE FILTER Reassembly

4. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

(a) Align and attach the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear assembly.

Text in Illustration

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

Text in Illustration

Torque : 85 Nm (867 kgf-cm, 63 ft-lbf)

NOTICE:
Do not disassemble the camshaft timing exhaust gear.

5. 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.

Text in Illustration

6. INSTALL NO. 2 CAMSHAFT

(a) Make sure that the valve rocker arms are installed as shown in the illustration.

Text in 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.

Text in Illustration

7. INSTALL CAMSHAFT

(a) Make sure that the valve rocker arms are installed as shown in the illustration.

Text in 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 camshaft to the camshaft housing as shown in the illustration.

Text in Illustration

8. INSTALL CAMSHAFT BEARING CAP

(a) Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.

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

Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)

(c) Using several steps, uniformly tighten the 11 bolts in the sequence shown in the illustration.

Torque : 16 Nm (163 kgf-cm, 12 ft-lbf)

(d) Check the torque of each bolt again.

9. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

(a) Check the camshaft timing gear position.

Text in Illustration

NOTICE:
* If the camshaft timing gear is set to the advanced position, do not let the camshaft timing gear rotate clockwise during installation.
* If the camshaft timing gear has rotated to the most retarded position, make sure to release the lock pin and set the camshaft timing gear to the most advanced position before tightening the camshaft timing gear.

(b) Install the camshaft timing gear as shown in the illustration.

Text in Illustration

(d) Align the paint mark with the matchmark to install the chain.

Text in Illustration

(e) Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear.

Text in Illustration

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

Text in Illustration

(g) Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear by hand.

NOTICE:
Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

(h) If the lock pin has not been released, release it.

(1) After cleaning and degreasing the intake side VVT oil hole on the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.

Text in Illustration

NOTICE:
Be sure to seal the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

(2) Make a hole in the adhesive tape covering the oil hole as shown in the illustration. (Procedure A)

(3) Apply approximately 200 kPa (2.0 kgf/ cm2, 29 psi) of air pressure to the hole made in procedure A to release the lock pin.

NOTICE:
* If air leaks out, reattach the adhesive tape.
* Cover the oil hole with a piece of cloth when applying air pressure to prevent oil from spraying.

(4) Forcibly turn the camshaft timing gear in the advance direction (counterclockwise).

HINT
Depending on the air pressure applied, the camshaft timing gear may turn in the advance direction without assistance by hand.

(5) Remove the adhesive tape from the No. 1 camshaft bearing cap.

(i) Using a wrench to hold the hexagonal portion of the No. 1 camshaft, install the bolt.

Torque : 85 Nm (867 kgf-cm, 63 ft-lbf)

NOTICE:
Be careful not to damage the cylinder head or spark plug tube with the wrench.

(j) 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.

Text in Illustration

10. ADD ENGINE OIL Installation

11. INSTALL TIMING CHAIN GUIDE Installation

12. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Turn the crankshaft approximately 10° clockwise.

(b) Install a new gasket and the chain tensioner with the 2 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

NOTICE:
Make sure not to drop the gasket inside the timing chain cover.

(c) Remove the pin from the stopper plate.

13. CHECK 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.

Text in Illustration

(b) Check that the timing marks of the camshaft timing gears are as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration.

HINT
"A" is not a timing mark.

14. INSTALL TIMING CHAIN COVER PLATE

(a) Install a new gasket and the timing chain cover plate with the 4 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

NOTICE:
Using a 10 mm union nut wrench, tighten the A bolts. Use the torque value compensation formula to calculate the torque value for use when a torque wrench is combined with a tool such as a union nut wrench Service Precautions.

15. INSTALL TIMING CHAIN COVER TIGHT PLUG Reassembly

16. INSTALL RADIATOR RESERVE TANK ASSEMBLY

(a) Install the radiator reserve tank assembly with the 2 bolts.

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

17. INSTALL CRANKSHAFT POSITION SENSOR Installation

18. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Installation

19. INSTALL IGNITION COIL ASSEMBLY Installation

20. INSTALL ENGINE WIRE

(a) Connect the connectors and clamps, and install the engine wire to the engine with the bolts and nuts.

Nut A - Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

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

Bolt - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

21. INSTALL AIR CLEANER CASE SUB-ASSEMBLY Installation

22. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation

23. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

24. INSPECT FOR OIL LEAK

25. INSTALL REAR ENGINE UNDER COVER RH Installation

26. CONNECT FRONT FENDER LINER RH Installation

27. INSTALL FRONT WHEEL RH