Installation

2ZR-FXE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION

1. INSTALL NO. 1 CAMSHAFT BEARING

(a) Clean both surfaces of the bearings.

(b) Install the 2 No. 1 camshaft bearings.

(c) Using a vernier caliper, measure the distance between the bearing cap edge and the camshaft bearing edge.

Text in Illustration

Standard dimension (A - B):

0.7 mm (0.0276 in.) or less

NOTICE:
Position the bearings to the center of the bearing cap by measuring dimensions A and B.

2. INSTALL NO. 2 CAMSHAFT BEARING

(a) Clean both surfaces of the bearings.

(b) Install the 2 No. 2 camshaft bearings.

(c) Using a vernier caliper, measure the distance between the bearing cap edge and the camshaft bearing edge.

Text in Illustration

Standard dimension (A):

1.05 to 1.75 mm (0.0413 to 0.0689 in.)

NOTICE:
Position the bearings 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 BEARING CAP

(a) Apply engine oil to the camshaft journals, camshaft housings and bearing caps.

(b) Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.

Text in Illustration

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

6. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

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

Text in 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

Standard Seal Diameter:

Application Length A and B:

15 mm (0.591 in.)

NOTICE:
* Remove any oil from the contact surfaces.
* Install the camshaft housing within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.
* Do not start the engine for at least 2 hours after installation.

(c) Set the camshaft and No. 2 camshaft as shown in the illustration.

(d) Install the camshaft housing with the 17 bolts and tighten them 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 is 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 is 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 cylinder head.

7. INSTALL CAMSHAFT TIMING SPROCKET

(a) Tighten the flange bolt with the camshaft timing sprocket secured in place.

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

8. 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.

Text in Illustration

NOTICE:
Do not forcefully push in the camshaft timing gear. This may cause the camshaft straight pin tip to damage the installation surface of the camshaft timing gear.

(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.

Text in Illustration

NOTICE:
Do not turn the camshaft timing gear in the retard direction (clockwise).

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

Text in Illustration

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

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

(e) Check that the camshaft timing gear can move in the retard direction (clockwise) and lock it in the most retarded position.

Text in Illustration

9. INSTALL NO. 1 CHAIN VIBRATION DAMPER

(a) Install the chain vibration damper with the 2 bolts.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

10. SET NO. 1 CYLINDER TO TDC/COMPRESSION

(a) Temporarily install the crankshaft pulley bolt.

Text in Illustration

(b) Turn the crankshaft to position the timing gear key to the top.

(c) Check that the timing marks on the camshaft timing gear and camshaft timing sprocket are aligned as shown in the illustration.

Text in Illustration

(d) Remove the crankshaft pulley bolt.

11. INSTALL CHAIN SUB-ASSEMBLY

(a) Align the mark plate (orange) with the timing mark as shown in the illustration and install the chain.

Text in Illustration

HINT
* Be sure to position the mark plate at the front of the engine.
* The mark plate on the camshaft side is colored orange.
* Do not pass the chain around the sprocket of the camshaft timing gear. Only place it on the sprocket.
* Pass the chain through the No. 1 vibration damper.

(b) Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear counterclockwise to align the mark plate (orange) and timing mark, and then install the chain.

(c) Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear clockwise.

HINT
To tension the chain, slowly turn the camshaft timing gear clockwise to prevent the chain from being misaligned.

(d) Align the mark plate (yellow) and timing mark and install the chain to the crankshaft timing gear.

Text in Illustration

HINT
The mark plate on the crankshaft side is colored pink.

12. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

(a) Check each timing mark at TDC/compression.

Text in Illustration

13. 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)

14. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the chain tensioner slipper to the cylinder block.

15. INSTALL TIMING CHAIN COVER OIL SEAL Installation

16. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Installation

17. INSTALL CRANKSHAFT PULLEY Installation

18. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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

Text in Illustration

NOTICE:
Make sure that the cam engages the first tooth of the plunger to allow the hook to pass over the pin.

(b) Install a new gasket, the bracket and chain tensioner with the 2 nuts.

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

NOTICE:
If the hook releases the plunger while the chain tensioner is being installed, set the hook again.

(c) Rotate the crankshaft counterclockwise slightly and check that the hook is released.

Text in Illustration

(d) Turn the crankshaft clockwise and check that the plunger is extended.

Text in Illustration

19. INSTALL SPARK PLUG TUBE GASKET Reassembly

20. INSTALL CYLINDER HEAD COVER GASKET Reassembly

21. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Reassembly

22. INSTALL IGNITION COIL ASSEMBLY Installation

23. INSTALL FUEL INJECTOR ASSEMBLY Installation

24. INSTALL NO. 1 DELIVERY PIPE SPACER Installation

25. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY Installation

26. INSTALL FUEL VAPOR FEED PIPE Installation

27. INSTALL INTAKE MANIFOLD Installation

28. INSTALL EGR WITH COOLER PIPE SUB-ASSEMBLY Installation

29. INSTALL EGR VALVE ASSEMBLY Installation

30. INSTALL EGR PIPE ASSEMBLY Installation

31. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE Installation

32. INSTALL THROTTLE BODY ASSEMBLY Installation

33. INSTALL ENGINE HANGERS Installation

34. REMOVE ENGINE STAND Installation

35. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

Installation