Installation

2AZ-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION

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.





(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.
NOTICE: Be sure not to turn the camshaft timing gear to the retard angle side (the right angle).





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





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





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





(c) Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps into the cylinder head.
(d) Apply a light coat of engine oil on 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 on the cylinder head with the paint mark on the chain aligned with the timing mark on the camshaft timing sprocket.





(c) While holding the No. 2 camshaft by hand, temporarily tighten the camshaft timing sprocket set bolt.





(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) While holding the camshaft with a wrench, tighten the camshaft timing sprocket set bolt.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)
NOTICE: Be careful not to damage the valve lifter.





(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.
4. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY





(a) Release the ratchet pawl, then fully push in the plunger and hook the hook to the pin so that the plunger is in the position shown in the illustration.





(b) Install a new gasket and the chain tensioner with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: When installing the chain tensioner, set the hook again if the hook releases the plunger.





(c) Turn the crankshaft counterclockwise, then disconnect the plunger knock pin from the hook.





(d) Turn the crankshaft clockwise, then check that the plunger is extended.
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 surface.
(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 surface.
- Install the oil pan within 3 minutes of applying seal packing.
- Do not add engine oil for at least 2 hours after installing the oil pan.





(c) Install the cylinder head cover with the 8 bolts and 2 nuts.
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 2 engine wires with the 2 bolts.
Torque: 8.4 Nm (86 kgf-cm, 74 in-lbf)





(e) Connect the 2 ventilation hoses to the cylinder head cover.
9. INSTALL SPARK PLUG Installation
10. INSTALL IGNITION COIL ASSEMBLY Installation
11. INSPECT FOR ENGINE OIL LEAK
12. INSPECT IGNITION TIMING Engine
13. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY Installation
14. INSTALL REAR ENGINE UNDER COVER RH