Installation
2TR-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION
1. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
(a) Put the camshaft timing gear and camshaft together by aligning the key groove and straight pin.
(b) Gently press the gear against the camshaft, and turn the gear. Push further at the position where the pin fits into the groove.
CAUTION:
Be sure not to turn the camshaft timing gear to the retard angle side (to the right angle).
(c) Check that there is no clearance between the gear's fringe and the camshaft.
(d) Tighten the fringe bolt with the camshaft timing gear fixed.
Torque : 78 Nm (795 kgf-cm, 58 ft-lbf)
(e) Check that the camshaft timing gear can move to the retard angle side (the right angle), and is locked in the extreme retard position.
2. INSTALL CAMSHAFT
NOTICE:
Check that the valve rocker arm is correctly set as shown in the illustration.
(a) Apply clean engine oil to the camshaft's cam portion and the cylinder head journals.
(b) Install the chain onto the camshaft timing gear, with the painted mark of the link aligned with the timing mark of the camshaft timing gear.
(c) Set the 2 camshafts as shown in the illustration.
NOTICE:
Align the paint mark with the timing mark before setting the camshaft.
(d) Provisionally install the No. 1 camshaft bearing cap.
(e) Check the proper location of each No. 2 camshaft bearing cap and install each one.
(f) Install a new O-ring onto the No. 1 camshaft bearing cap.
(g) Provisionally install the camshaft oil delivery pipe.
(h) Tighten the bolts in the order shown in the illustration.
Torque : 12 Nm (122 kgf-cm, 9 ft-lbf for bolt A)
Torque : 16 Nm (158 kgf-cm, 11 ft-lbf for bolts except bolt A)
(i) Check that each timing mark is set in the position shown in the illustration.
(j) Install the timing chain onto the camshaft timing gear, with the paint mark aligned with the timing mark on the camshaft timing gear.
(k) Align the No. 2 camshaft straight pin and camshaft timing gear straight pin hole. Then install the camshaft timing gear onto the No. 2 camshaft.
NOTICE:
If the straight pin and straight pin hole are difficult to align, slightly rotate the No. 2 camshaft to the left and right using the hexagonal lobe of the camshaft. Then attempt to align them again.
(l) Hold the hexagonal lobe of the No. 2 camshaft with the adjustable wrench.
(m) Tighten the bolt.
Torque : 78 Nm (795 kgf-cm, 58 ft-lbf)
(n) Remove the 3.0 mm (0.118 in.) diameter bar from the chain tensioner.
(o) Apply adhesive to 2 or 3 threads of the timing gear case with head straight screw plug.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(p) Using a 10 mm socket hexagon wrench, install the timing gear case with head straight screw plug.
Torque : 17 Nm (170 kgf-cm, 12 ft-lbf)
3. INSTALL TIMING CHAIN GUIDE
(a) Install a new O-ring onto the camshaft bearing cap.
(b) Install the timing chain guide with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
4. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(a) 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 cylinder head cover within 3 minutes of applying the seal packing.
* Do not apply engine oil for at least 2 hours of installation.
(b) Provisionally install the cylinder head cover with the 19 bolts and 2 nuts.
(c) Tighten bolts A shown in the illustration.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
(d) Tighten bolts B and nuts shown in the illustration.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
(e) Tighten bolts A again.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
(f) Connect the ventilation hose.
(g) Install the ignition coils with the bolts.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
(h) Install the engine wire harness clamps.
(i) Connect the camshaft position sensor connector.
(j) Connect the VSV connector.
(k) Connect the throttle with motor body connector.
(l) Connect the ignition coil connectors.
5. INSTALL INTAKE AIR CONNECTOR Installation
6. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation
7. INSTALL FAN SHROUD Installation
8. INSTALL RADIATOR SUPPORT TO FRAME SEAL LH Installation
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque : 3.9 Nm (40 kgf-cm, 35 in-lbf)
10. ADD ENGINE COOLANT Service and Repair
11. CHECK FOR ENGINE COOLANT LEAKAGE Testing and Inspection
12. CHECK FOR ENGINE OIL LEAKAGE
13. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (for Pre Runner and 4WD Type)
(a) Install the No. 1 engine under cover with the 4 bolts.
Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)