Installation

2ZR-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION

1. INSTALL NO. 1 CAMSHAFT BEARING

(a) Clean the 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 to the No. 1 camshaft bearing cap.

(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

NOTICE:
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 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 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.)

NOTICE:
Position the bearing to the center of the bearing cap by measuring dimension A.

3. 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.

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) Install the camshaft to the camshaft housing.

5. 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 knock pin of the camshaft is positioned 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.

6. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

(a) Check that the knock pin is installed on the camshaft.

(b) Hold up the chain and align the matchmark on the camshaft timing gear assembly and the paint mark on the chain.

(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) Using SST and a wrench, hold the hexagonal portion of the camshaft and fix the camshaft timing gear assembly to the camshaft with the bolt.

SST : 09249-37010

without SST - Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)

without SST - Torque : 39 Nm (398 kgf-cm, 29 ft-lbf)

NOTICE:
When tightening the bolts, do not allow the camshaft timing gear assembly to rotate.

HINT
* 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.

(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.

7. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

(a) Check that the knock pin is installed on the camshaft.

(b) Hold up the chain and align the matchmark on the camshaft timing gear assembly and the paint mark on the chain.

NOTICE:
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.

(d) Using a wrench, hold the hexagonal portion of the No. 2 camshaft and fix the camshaft timing exhaust gear assembly to the No. 2 camshaft with the bolt.

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

8. INSTALL NO. 2 CHAIN VIBRATION DAMPER

(a) Install the No. 2 chain vibration damper with the 2 bolts.

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

9. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Reassembly

10. INSTALL SERVICE COVER

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

(b) Make sure to clean and degrease the fitting surfaces of the service cover and timing chain cover so that they are free of grease, water or any contamination.

(c) Apply a continuous bead of seal packing (Diameter 5.0 mm (0.197 in.)) as shown in the illustration.

NOTICE:
* Remove any oil from the contact surface.
* Install the service cover within 3 minutes after applying seal packing.
* Do not add engine oil within 2 hours after installing the service cover.

(d) Install the service cover to the timing chain cover with the 5 bolts.

Torque : 9.1 Nm (93 kgf-cm, 81 in-lbf)

11. 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.

12. REMOVE CYLINDER HEAD COVER GASKET Reassembly

13. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Reassembly

14. INSTALL AIR TUBE ASSEMBLY

(a) Install the air tube assembly with the 2 bolts.

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

(b) Connect the 4 hoses.

15. 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)

16. CONNECT NO. 2 VENTILATION HOSE

(a) Connect the No. 2 ventilation hose.

17. INSTALL RADIO SETTING CONDENSER Installation

18. INSTALL IGNITION COIL ASSEMBLY Installation

19. INSPECT FOR ENGINE OIL LEAK

20. INSTALL NO. 2 CYLINDER HEAD COVER Installation

21. INSTALL OUTER COWL TOP PANEL Installation

22. INSTALL FRONT AIR SHUTTER SEAL RH Installation

23. INSTALL FRONT WIPER MOTOR AND LINK Installation

24. INSTALL COWL TOP VENTILATOR LOUVER LH Installation

25. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation

26. INSTALL HOOD TO COWL TOP SEAL Installation

27. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation

28. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation

29. INSTALL FRONT WIPER ARM HEAD CAP Installation

30. INSPECT IGNITION TIMING Engine

31. INSPECT ENGINE IDLING SPEED Engine