2ZR-FXE (ENGINE MECHANICAL): CAMSHAFT: INSTALLATION; 2020 - 2025 MY Corolla Corolla HV [01/2019

Last Modified: 07-31-2024	6.11:8.1.0	Doc ID: RM100000001GMHJ
Model Year Start: 2020	Model: Corolla	Prod Date Range: [01/2019 - ]
Title: 2ZR-FXE (ENGINE MECHANICAL): CAMSHAFT: INSTALLATION; 2020 - 2025 MY Corolla Corolla HV [01/2019 - ]

INSTALLATION

PROCEDURE

1. INSTALL NO. 1 CAMSHAFT BEARING

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2. INSTALL NO. 2 CAMSHAFT BEARING

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3. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

HINT:

Perform "Inspection After Repair" after replacing the camshaft timing gear assembly.

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(a) Secure the hexagonal portion of the camshaft in a soft jaw vise.

(b) Align and fit the knock pin of the camshaft to the knock pin hole of the camshaft timing gear assembly.

*a	Knock Pin
*b	Knock Pin Hole

*1	Camshaft Timing Gear Assembly
*a	Camshaft Flange
*b	No Gap

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

Torque:

54 N·m {551 kgf·cm, 40 ft·lbf}

NOTICE:

When tightening the bolt, do not allow the camshaft timing gear assembly to rotate.

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

Lock

4. SET NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

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5. INSTALL CAMSHAFT

HINT:

Perform "Inspection After Repair" after replacing the camshaft.

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(a) Clean the camshaft journals.

(b) Apply a light coat of engine oil to the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.

*a	Paint Mark
*b	Timing Mark

6. INSTALL NO. 2 CAMSHAFT

HINT:

Perform "Inspection After Repair" after replacing the No. 2 camshaft.

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(a) Clean the No. 2 camshaft journals.

(b) Apply a light coat of engine oil to the No. 2 camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.

7. 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 for 1 camshaft bearing cap, install the camshaft bearing cap with the bolts in the order shown in the illustration.

*a	Service bolt and spacer (Used to temporarily secure the camshaft housing sub-assembly)	*b	Knock Pin
*c	Paint Mark	*d	Timing Mark
*e	The removal order of the service bolts and spacers for temporarily tightening the camshaft housing sub-assembly	*f	The installation order of the parts

Torque:

27 N·m {275 kgf·cm, 20 ft·lbf}

NOTICE:

If the bolts are loosened all at once, seal packing on the camshaft housing sub-assembly and cylinder head sub-assembly may separate, resulting in oil leaks. Therefore, be sure to remove the service bolts and spacers from one camshaft bearing cap at a time.

HINT:

Make sure that the orientation of the straight pin, timing mark and paint mark of the camshaft are as shown in the illustration.

(b) Tighten the 10 bolts in the order shown in the illustration.

Torque:

16 N·m {163 kgf·cm, 12 ft·lbf}

8. INSTALL CAMSHAFT TIMING SPROCKET

(a) Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft slightly counterclockwise to release the chain sub-assembly.

NOTICE:

Do not turn the camshaft more than necessary.

*a	Paint Mark
*b	Timing Mark

(b) Align the paint mark with the timing mark to install the chain sub-assembly.

(c) Using SST, a 14 mm union nut wrench and a wrench, hold the hexagonal portion of the No. 2 camshaft and install the camshaft timing sprocket to the No. 2 camshaft.

SST: 09961-00950

Torque:

Specified tightening torque

54 N*m (551 kgf*cm, 40 ft.*lbf)

HINT:

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
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When using a 14 mm union nut wrench (fulcrum length of 25 mm (0.984 in.)) + SST (fulcrum length of 150 mm (5.91 in.)) + torque wrench (fulcrum length of 255 mm (10.0 in.)): 32 N*m (326 kgf*cm, 24 ft.*lbf)

*a	14 mm Union Nut Wrench
*b	Torque Wrench Fulcrum Length
*c	Hold
*d	Turn

9. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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10. INSTALL NO. 2 CHAIN VIBRATION DAMPER

(a) Using SST, install the No. 2 chain vibration damper to the No. 1 camshaft bearing cap with the 2 bolts.

SST: 09961-00950

Torque:

Specified tightening torque

10 N*m (102 kgf*cm, 7 ft.*lbf)

HINT:

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
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When using SST ((fulcrum length of 150 mm (5.91 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 5.2 N*m (53 kgf*cm, 46 in.*lbf)

*a	Torque Wrench Fulcrum Length

11. SET NO. 1 CYLINDER TO TDC (COMPRESSION)

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12. INSTALL SPARK PLUG TUBE GASKET

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13. INSTALL CYLINDER HEAD COVER GASKET

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14. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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15. INSTALL FUEL VAPOR FEED PIPE

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16. INSTALL PURGE VALVE (PURGE VSV)

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17. CONNECT NO. 9 WATER BY-PASS HOSE

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18. CONNECT NO. 8 WATER BY-PASS HOSE

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19. INSTALL EGR PIPE ASSEMBLY

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20. CONNECT FUEL VAPOR FEED HOSE

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21. CONNECT ENGINE WIRE

(a) Connect the engine wire to the cylinder head cover sub-assembly with the bolt.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(b) Engage the 4 clamps.

22. INSTALL CAMSHAFT POSITION SENSOR

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23. INSTALL IGNITION COIL ASSEMBLY

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24. CONNECT NO. 2 VENTILATION HOSE

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25. CONNECT FLOOR SHIFT TRANSMISSION CONTROL SELECT CABLE

(a) Connect the floor shift transmission control select cable to the cylinder head cover sub-assembly with the bolt.

Torque:

12 N·m {122 kgf·cm, 9 ft·lbf}

26. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

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27. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

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28. INSTALL WINDSHIELD WIPER MOTOR AND LINK

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29. ADD ENGINE COOLANT (for Engine)

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30. INSPECT FOR COOLANT LEAK (for Engine)

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31. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

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