CAMSHAFT INSTALLATION


  1. INSTALL CAMSHAFTS

    A01BFILE02

    1. Using the crankshaft pulley bolt, set the No. 1 cylinder to 90° BTDC/compression.

      Tech Tips

      Set the No. 1 cylinder to 90° BTDC/compression to avoid interference with the piston top and valve head.

    2. A01BHTRE02

      Install the camshaft.


      1. Apply MP grease to the thrust portion of the camshaft.

      2. Place the camshaft on the cylinder head, facing the key groove upward.

      3. A01BCWVE01

        Align the timing marks (1 dot mark) of the camshaft drive and driven main gears, and set the No. 2 camshaft in place.

    3. A01BCC1E04

      Remove any old packing (FIPG) material from the camshaft bearing cap.

    4. Apply seal packing to the specified areas shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      4 mm (0.16 in.)

      Note


      • Do not allow FIPG to come into contact with the oil passage of the bearing cap.

      • After applying FIPG, install the camshaft bearing caps within 3 minutes and tighten the bolts within 15 minutes.

      • Do not start the engine for at least 2 hours after the installation.


      1. A01BANQE01

        Install the 5 bearing caps in the proper locations.

      2. A01BH68E02

        Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

      3. Install and uniformly tighten the 15 bearing cap bolts in several passes in the sequence shown in the illustration.

        Torque:
        19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  2. INSTALL CAMSHAFT SETTING OIL SEAL


    1. Apply MP grease to the lip of a new oil seal.

    2. A01BDHOE01

      Using SST and a hammer, tap in the oil seal until its surface is flush with the oil seal retainer edge.

      SST
      09608-06041

  3. SET NO. 1 CYLINDER TO TDC / COMPRESSION

    A01BES8E03

    1. Align the alignment marks of the crankshaft pulley and timing gear case cover by rotating the crankshaft clockwise.

      Tech Tips

      Make sure that both cam-noses (intake side and exhaust side) of the No. 1 cylinder face upward.

  4. INSPECT VALVE CLEARANCE

    A01BGD1E03

    1. Check only the valves indicated.


      1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

        Standard valve clearance (Cold)
        Intake Exhaust
        0.20 to 0.30 mm (0.008 to 0.012 in.) 0.35 to 0.45 mm (0.014 to 0.018 in.)

        Write down the valve clearance measurements that are not within the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed.

    2. Turn the crankshaft 360° to set the No. 4 cylinder to TDC / compression.

    3. A01BH8PE02

      Check only the valves indicated.


      1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

        Standard valve clearance
        Intake Exhaust
        0.20 to 0.30 mm (0.008 to 0.012 in.) 0.35 to 0.45 mm (0.014 to 0.018 in.)

        Write down the valve clearance measurements that are not within the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed.

  5. ADJUST VALVE CLEARANCE


    1. Remove the camshafts Click here.

    2. Remove the 8 valve lifters.

    3. A01BF23E01

      Using a micrometer, measure the thickness of the removed lifter.

    4. Calculate the thickness of a new lifter so that the valve clearance comes within the specified value.

      A B C
      New lifter thickness Used lifter thickness Measured valve clearance
      New lifter thickness
      Intake A = B + (C - 0.25 mm (0.0098 in.))
      Exhaust A = B + (C - 0.40 mm (0.00158 in.))

    5. Select a new lifter with a thickness as close as possible to the calculated values.

      Tech Tips

      Valve lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).

      A01BG3IE01
      A01BAD4E01
      Standard intake valve clearance (Cold)
      0.20 to 0.30 mm (0.008 to 0.012 in.)
      EXAMPLE
      The 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0158 in.). Replace the 5.250 mm (0.2067 in.) shim with a No. 40 lifter.
      New lifter thickness (mm (in.))
      Shim No. Thickness Shim No. Thickness Shim No. Thickness
      06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181)
      08 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189)
      10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197)
      12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205)
      14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213)
      16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220)
      18 5.180 (0.2039) 42 5.420 (0.2134) 66 5.660 (0.2228)
      20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236)
      22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244)
      24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252)
      26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260)
      28 5.280 (0.2079) 52 5.520 (0.2173) - -
      A01BEDME01
      A01BBJGE01
      A01BDZZE01
      Standard exhaust valve clearance (Cold)
      0.35 to 0.45 mm (0.014 to 0.018 in.)
      EXAMPLE
      The 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.480 mm (0.0189 in.). Replace the 5.340 mm (0.2102 in.) shim with a No. 42 lifter.
      New lifter thickness (mm (in.))
      Shim No. Thickness Shim No. Thickness Shim No. Thickness
      06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181)
      08 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189)
      10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197)
      12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205)
      14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213)
      16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220)
      18 5.180 (0.2039) 42 5.420 (0.2134) 66 5.660 (0.2228)
      20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236)
      22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244)
      24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252)
      26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260)
      28 5.280 (0.2079) 52 5.520 (0.2173) - -

    6. Install the selected valve lifters.

    7. Install the camshafts Click here.

  6. INSTALL NO. 2 TIMING BELT COVER

    A01BD0OE01

    1. Apply seal packing (FIPG) to the specified areas shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note

      After applying FIPG, install the No. 2 timing belt cover within 3 minutes and tighten the bolts and nut within 15 minutes.

    2. Install the No. 2 timing belt cover with the 4 bolts and nut.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  7. INSTALL CAMSHAFT TIMING PULLEY

    A01BG3CE01

    1. Install the camshaft timing pulley.

    2. Fasten the bolt of the camshaft timing pulley while holding the camshaft with a wrench.

      Torque:
      98 N*m  { 1000 kgf*cm, 72 ft.*lbf }

  8. INSTALL INJECTOR ASSEMBLY

    Refer to the procedures under "INSTALL INJECTOR ASSEMBLY" Click here.

  9. INSTALL TIMING BELT

    Refer to the procedures under "INSTALL TIMING BELT" Click here.