Question 1

How to install the valve timing controller assembly and Cam Gear on Toyota Celica?

Accepted Answer

Oiling the intake camshaft tip and extending it 16mm allows for correct installation of the valve timing controller assembly by setting its timing mark to match the knock pin before mounting onto the camshaft without excessive force. Set the knock pin hole on the camshaft timing sprocket to align with the camshaft knock pin before you use the sprocket to exhaust the camshaft and then install a temporary timing sprocket bolt. Use a wrench to hold the hexagon wrench head of the camshaft before tightening the timing sprocket bolt to 54 Nm (551 kgf-cm, 40 ft-lbf). To position the No.1 cylinder at TDC/compression stage the hexagonal wrench head portion of camshafts needs adjustment for point mark alignment on camshaft timing sprockets which enables continuous rotation of the crankshaft using a crankshaft pulley bolt until the key on the crankshaft faces upwards. Wind the chain vibration damper into place using two bolts which should reach a torque of 9.0 Nm (92 kgf-cm, 80 in.-lbf) for 1ZZ-FE and 20.5 Nm (209 kgf-cm, 15 ft-lbf) for 2ZZ-GE. The timing chain installation for the crankshaft sprocket requires alignment of the yellow link to the timing mark while using Special Service Tool: 09223-22010 only when needed. For 1ZZ-FE engines align the yellow links on camshaft timing sprockets while 2ZZ-GE engines need to align the orange links. Install the chain tensioner slipper with bolt to achieve a torque value of 18.5 Nm (189 kgf-cm, 14 ft-lbf) for 1ZZ-FE or 20.5 Nm (209 kgf-cm, 15 ft-lbf) for 2ZZ-GE. While doing this check that the slipper moves to engage on the cylinder head stopper while avoiding crankshaft rotation. Installation of the crank angle sensor plate requires "F" facing forward while for 1ZZ-FE you must replace packing material from the timing chain cover and water pump contact areas before cleaning thoroughly with 1.5 mm nozzle seal packing (Part No. 08826-00100 or equivalent). Assembly must complete within 3 minutes. Secure the timing chain cover alongside the O-ring by using 16 bolts and 2 nuts which need uniform tightening to appropriate torque values while applying Part No. 08826-00080 or equivalent seal packing at 2 locations. The 2ZZ-GE installation process for timing chain cover and water pump requires the same method as before with proper seal packing techniques and balanced bolt tightening process. Fitting up 2ZZ-GE requires the exhaust manifold alongside the exhaust manifold stay and front exhaust pipe while 1ZZ-FE uses the RH engine mounting bracket which needs seal packing (Part No. 08826-00080 or equivalent) before torque reaches 47 Nm (479 kgf-cm, 35 ft-lbf). For 2ZZ-GE mount the normal right engine bracket by using 4 bolts that require 49 Nm (500 kgf-cm, 36 ft-lbf) torque. The drive belt tensioner should receive inspection for leakage and cracking before its bolts and nut receive their specified torque values. Use Special Service Tool 09960-10010 (or its equivalent tools 09962-01000, 09963-01000) for installing the crankshaft pulley bolt and achieve the specified torque measurements. Install the chain tensioner while achieving correct tension before performing valve timing checks by positioning the crankshaft pulley at mark "0" with synchronized camshaft timing sprocket marks. To install the cylinder head cover of 1ZZ-FE, use seal packing (Part No. 08826-00080 or equivalent) and secure it properly while torquing all bolts and nuts before connecting PCV hoses and the ignition coil. The installation process for the 2ZZ-GE cylinder head cover should proceed similarly with careful attention given to proper torques and connections. The RH engine mounting insulator requires installation in both engine types with torque set to 52 Nm (530 kgf-cm, 38 ft-lbf). The installation process includes attaching the PS pump to the generator and drive belt and air switching valve for 2ZZ-GE and RH engine under cover before the RH front wheel goes on. In conclusion, add the motor coolant before installing front fender apron seals and upper radiator support seals while testing for any coolant leakage when starting the engine.

Question 2

How to service and repair the Cam Gear/sprocket on Toyota Solara?

Accepted Answer

Starting the camshaft gear/sprocket repair requires removal of the front wheel RH as well as front fender apron seal RH and engine cover sub-assembly No.1 and engine moving control rod with bracket by taking out the 3 bolts. The following service order begins with removing engine mounting stay No.2 RH and engine mounting bracket No.2 RH before proceeding to take off the fan and generator V belt. To service and repair the crankshaft pulley first expand the pulley bolt with Special Service Tool: 09960-10010 and then remove the bolt and pulley completely using Special Service Tool: 09950-40011. Use tools 09308-10010 or 09950-60010 (09951-00200) to extract the timing gear case or timing chain case r oil seal. Before installing an oil seal place MP grease on its lips after inspecting for foreign contaminants and strike it in with Special Service Tool: 09223-22010 and a hammer until it reaches the rear oil seal retainer edge. Remove excess grease from the crankshaft. Install the crankshaft pulley through the pulley set key of its key groove while utilizing Special Service Tool: 09960-10010 (09962-01000, 09963-01000) to tighten the pulley bolt to 170 Nm (1,733 kgf-cm, 125 ft. lbs.). After installing the fan and generator V belt the technician should torque the engine mounting bracket No.2 RH to 52 Nm (531 kgf-cm, 38 ft. lbs.) and the engine mounting stay No.2 RH to 64 Nm (653 kgf-cm, 47 ft. lbs.). The front wheel RH reinstallation procedure begins after bracket and 3 bolting the engine moving control rod with bracket which needs to be torqued to 64 Nm (653 kgf-cm, 47 ft. lbs.). Afterward, check for engine oil leaks.

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