CAMSHAFT INSTALLATION

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.


  1. INSTALL CAMSHAFTS


    1. A01BFILE02

      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 between 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, with the key groove facing 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

    A01BES8E04
    Text in Illustration
    *1 Matchmark

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

      Tech Tips

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

  4. INSPECT VALVE CLEARANCE

    A01BGD1E04
    Text in Illustration
    *1 Exhaust
    *2 Intake
    *a Front

    1. Check only the valves indicated.


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

        Standard Valve Clearance (Cold)
        Item Specified Condition
        Intake 0.20 to 0.30 mm (0.008 to 0.012 in.)
        Exhaust 0.35 to 0.45 mm (0.014 to 0.018 in.)

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

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

    3. A01BH8PE03
      Text in Illustration
      *1 Exhaust
      *2 Intake
      *a Front

      Check only the valves indicated.


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

        Standard Valve Clearance
        Item Specified Condition
        Intake 0.20 to 0.30 mm (0.008 to 0.012 in.)
        Exhaust 0.35 to 0.45 mm (0.014 to 0.018 in.)

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

  5. ADJUST VALVE CLEARANCE


    1. Remove the camshafts Click here.

    2. Remove the 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 is within the specified range.

      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.).

      A01BCV9E01
      Text in Illustration
      *1 Valve Lifter Selection Chart (Intake) *2 Installed lifter thickness mm (in.)
      *3 Measured clearance mm (in.) - -
      Standard intake valve clearance (Cold)
      0.20 to 0.30 mm (0.008 to 0.012 in.)
      EXAMPLE
      A 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.) lifter with a No. 40 lifter.
      New Lifter Thickness
      Lifter No. Specified Condition Lifter No. Specified Condition Lifter No. Specified Condition
      06 5.060 mm (0.1992 in.) 30 5.300 mm (0.2087 in.) 54 5.540 mm (0.2181 in.)
      08 5.080 mm (0.2000 in.) 32 5.320 mm (0.2094 in.) 56 5.560 mm (0.2189 in.)
      10 5.100 mm (0.2008 in.) 34 5.340 mm (0.2102 in.) 58 5.580 mm (0.2197 in.)
      12 5.120 mm (0.2016 in.) 36 5.360 mm (0.2110 in.) 60 5.600 mm (0.2205 in.)
      14 5.140 mm (0.2024 in.) 38 5.380 mm (0.2118 in.) 62 5.620 mm (0.2213 in.)
      16 5.160 mm (0.2031 in.) 40 5.400 mm (0.2126 in.) 64 5.640 mm (0.2220 in.)
      18 5.180 mm (0.2039 in.) 42 5.420 mm (0.2134 in.) 66 5.660 mm (0.2228 in.)
      20 5.200 mm (0.2047 in.) 44 5.440 mm (0.2142 in.) 68 5.680 mm (0.2236 in.)
      22 5.220 mm (0.2055 in.) 46 5.460 mm (0.2150 in.) 70 5.700 mm (0.2244 in.)
      24 5.240 mm (0.2063 in.) 48 5.480 mm (0.2157 in.) 72 5.720 mm (0.2252 in.)
      26 5.260 mm (0.2071 in.) 50 5.500 mm (0.2165 in.) 74 5.740 mm (0.2260 in.)
      28 5.280 mm (0.2079 in.) 52 5.520 mm (0.2173 in.) - -
      A01BHLKE01
      Text in Illustration
      *1 Valve Lifter Selection Chart (Exhaust) *2 Installed lifter thickness mm (in.)
      *3 Measured clearance mm (in.) - -
      Standard exhaust valve clearance (Cold)
      0.35 to 0.45 mm (0.014 to 0.018 in.)
      EXAMPLE
      A 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.) lifter with a No. 42 lifter.
      New Lifter Thickness
      Lifter No. Specified Condition Lifter No. Specified Condition Lifter No. Specified Condition
      06 5.060 mm (0.1992 in.) 30 5.300 mm (0.2087 in.) 54 5.540 mm (0.2181 in.)
      08 5.080 mm (0.2000 in.) 32 5.320 mm (0.2094 in.) 56 5.560 mm (0.2189 in.)
      10 5.100 mm (0.2008 in.) 34 5.340 mm (0.2102 in.) 58 5.580 mm (0.2197 in.)
      12 5.120 mm (0.2016 in.) 36 5.360 mm (0.2110 in.) 60 5.600 mm (0.2205 in.)
      14 5.140 mm (0.2024 in.) 38 5.380 mm (0.2118 in.) 62 5.620 mm (0.2213 in.)
      16 5.160 mm (0.2031 in.) 40 5.400 mm (0.2126 in.) 64 5.640 mm (0.2220 in.)
      18 5.180 mm (0.2039 in.) 42 5.420 mm (0.2134 in.) 66 5.660 mm (0.2228 in.)
      20 5.200 mm (0.2047 in.) 44 5.440 mm (0.2142 in.) 68 5.680 mm (0.2236 in.)
      22 5.220 mm (0.2055 in.) 46 5.460 mm (0.2150 in.) 70 5.700 mm (0.2244 in.)
      24 5.240 mm (0.2063 in.) 48 5.480 mm (0.2157 in.) 72 5.720 mm (0.2252 in.)
      26 5.260 mm (0.2071 in.) 50 5.500 mm (0.2165 in.) 74 5.740 mm (0.2260 in.)
      28 5.280 mm (0.2079 in.) 52 5.520 mm (0.2173 in.) - -

    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 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. Clean the bolts and their holes.

    3. Apply adhesive to 2 or 3 threads at the end of 4 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. 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


    1. A01BG3CE01

      Install the camshaft timing pulley.

    2. Install 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


  9. INSTALL TIMING BELT

    Click here