CAMSHAFT INSTALLATION

Tech Tips

Perform "Inspection After Repairs" after replacing the camshaft, No. 2 camshaft, camshaft timing gear assembly or camshaft timing exhaust gear assembly Click here.

INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

Tech Tips

Perform "Inspection After Repairs" after replacing the camshaft timing exhaust gear assembly Click here.

Text in Illustration

*a Hexagonal Portion

Using SST, grip the hexagonal portion, and then secure the SST and No. 2 camshaft in a vise as shown in the illustration.

SST

09212-31010
Note
- Do not damage the No. 2 camshaft.
- Never grip areas other than the hexagonal portion, as this may cause damage.
Text in Illustration

*a Straight Pin Hole

*b Straight Pin

Align and attach the straight pin of the No. 2 camshaft with the straight pin hole of the camshaft timing exhaust gear assembly.

Text in Illustration
*a	Hexagonal Portion

Text in Illustration
*a	Straight Pin Hole
*b	Straight Pin

Text in Illustration
*1	Camshaft Timing Exhaust Gear Assembly
*a	INCORRECT
*b	CORRECT
*c	Clearance
*d	Camshaft Flange
*e	No Clearance

Check that there is no clearance between the camshaft timing exhaust gear assembly and camshaft flange.

Note

Be sure not to remove the other 4 bolts. If removing the bolts, exchange the camshaft timing exhaust gear assembly.

Fix the camshaft timing exhaust gear assembly with the flange bolt.

Torque:

78 N*m { 795 kgf*cm, 58 ft.*lbf }

INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

Tech Tips

Perform "Inspection After Repairs" after replacing the camshaft timing gear assembly Click here.

Text in Illustration

*a Hexagonal Portion

Using SST, grip the hexagonal portion, and then secure the SST and camshaft in a vise as shown in the illustration.

SST

09212-31010
Note
- Do not damage the camshaft.
- Never grip areas other than the hexagonal portion, as this may cause damage.
Text in Illustration

*a Straight Pin

*b Straight Pin Hole

Align the straight pin hole and straight pin and install the camshaft timing gear assembly to the camshaft.
Lightly press the gear against the camshaft and turn the gear. Push further at the position where the straight pin enters the straight pin hole.

Note

Be sure not to turn the camshaft timing gear assembly in the retard direction (the right angle).

Text in Illustration
*a	Hexagonal Portion

Text in Illustration
*a	Straight Pin
*b	Straight Pin Hole

Text in Illustration
*1	Camshaft Timing Gear Assembly
*a	INCORRECT
*b	CORRECT
*c	Clearance
*d	Camshaft Flange
*e	No Clearance

Check that there is no clearance between the camshaft timing gear assembly and the flange of the camshaft.

Note

Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break.
Be sure not to remove the other 3 bolts. If removing the bolts, exchange the camshaft timing gear assembly.

With the camshaft timing gear assembly fixed in place, install the flange bolt.

Torque:

78 N*m { 795 kgf*cm, 58 ft.*lbf }
Check that the camshaft timing gear assembly can move in the retard direction (the right angle), and is locked at the most retarded position.

INSTALL CAMSHAFT AND NO. 2 CAMSHAFT

Tech Tips

Perform "Inspection After Repairs" after replacing the camshaft or No. 2 camshaft Click here.

Apply clean engine oil to the camshaft cams and cylinder head journals.
Install the chain sub-assembly to the camshaft timing gear assembly with the paint mark of the link aligned with the timing mark of the camshaft timing gear assembly.

Text in Illustration

*a Paint Mark

*b Timing Mark
Temporarily install the 4 No. 2 camshaft bearing caps using the 8 bolts as shown in the illustration.
Install the chain sub-assembly to the No. 2 camshaft, and then install the No. 2 camshaft to the cylinder head sub-assembly.

Tech Tips

Place the chain sub-assembly on the camshaft timing gear assembly but do not engage the teeth of the sprocket and the chain sub-assembly.

Text in Illustration
*a	Paint Mark
*b	Timing Mark

Move the camshaft in the direction shown in the illustration to loosen the chain sub-assembly, and align the paint mark on the camshaft timing gear assembly and chain sub-assembly and connect the chain sub-assembly to the camshaft timing gear assembly.

Text in Illustration
*a	Camshaft	*b	No. 2 Camshaft
*c	Chain Sub-assembly	*d	Timing Mark
*e	Paint Mark	-	-

Text in Illustration
*1	No. 1 Valve Rocker Arm Sub-assembly
*2	Valve Lash Adjuster Assembly
*3	Valve Stem Cap
*a	INCORRECT
*b	CORRECT

Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.

Temporarily install the No. 1 camshaft bearing cap and 4 No. 2 camshaft bearing caps using the 12 bolts.
Install the 20 bolts in the order shown in the illustration.

Torque:

16 N*m { 158 kgf*cm, 11 ft.*lbf }

INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

Text in Illustration
*a	Plunger
*b	Stopper Plate
*c	Hexagon Wrench

Move the stopper plate upward to release the lock and push the plunger deep into the tensioner.

Move the stopper plate downward to set the lock and insert a hexagon wrench into the hole of the stopper plate.
Install a new gasket and the No. 1 chain tensioner assembly with the bolt and nut.

Torque:

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

Note

Remove the hexagon wrench after installing the timing chain guide.
Install a new gasket to the timing chain cover plate.
Install the timing chain cover plate to the timing chain or belt cover sub-assembly with the 2 bolts.

Torque:

9.0 N*m { 92 kgf*cm, 80 in.*lbf }

INSTALL TIMING CHAIN GUIDE
1. Text in Illustration
  
  *1 O-ring
  
  Install a new O-ring and the timing chain guide with the 2 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }

Text in Illustration
*1	O-ring

CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

Check that the No. 1 cylinder is set to TDC/compression.

Text in Illustration
*a	Timing Mark
*b	Groove
*c	Approximately 13°

Rotate the crankshaft two full rotations, and then check that all timing marks are in the position shown in the illustration.

If the timing marks do not match, set the chain sub-assembly again.

INSTALL CYLINDER HEAD COVER CONNECTOR SUB-ASSEMBLY
1. Install a new No. 2 camshaft bearing cap oil hole gasket and 3 new No. 3 camshaft bearing cap oil hole gaskets to the camshaft bearing cap.
2. Install the cylinder head cover connector sub-assembly with the 2 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

Remove any old packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the cylinder head cover sub-assembly and cylinder head sub-assembly.
Apply seal packing as shown in the illustration.

Seal packing

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

Standard seal diameter

4.0 mm (0.157 in.)

Text in Illustration

Seal Packing Application Area
Note
- Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
- Do not add the engine oil for at least 4 hours after the installation.
- Do not start the engine for at least 4 hours after the installation.
Install a new No. 1 camshaft bearing cap oil hole gasket to the cylinder head cover spacer.
Install a new gasket to the cylinder head cover sub-assembly.

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

Standard seal diameter
4.0 mm (0.157 in.)

Text in Illustration
	Seal Packing Application Area

Text in Illustration
*1	Plate Washer and Seal Washer
	Bolt
	Nut

Install the cylinder head cover sub-assembly, 2 plate washers and 2 seal washers with the 21 bolts and 2 nuts, and tighten the 21 bolts and 2 nuts in the sequence shown in the illustration.

Torque:: 9.0 N*m { 92 kgf*cm, 80 in.*lbf }

Note

Make sure that the metal face of the seal washer is facing upward.

Connect the PCV hose to the PCV valve sub-assembly and slide the clip to secure the hose.

INSTALL IGNITION COIL ASSEMBLY
1. Install the 4 ignition coil assemblies with the 4 bolts.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
INSTALL INTAKE AIR CONNECTOR
1. Temporarily install the intake air connector to the throttle body assembly.
2. Connect the vacuum hose to the intake air connector.
3. Connect the No. 2 PCV hose to the cylinder head cover sub-assembly, and slide the clamp to secure the hose.
4. Install the intake air connector with the 2 bolts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
5. Tighten the 2 hose clamps.
  
  Torque:
  
  for clamp A
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
INSTALL AIR PRESSURE SENSOR
1. Install the air pressure sensor with the bolt.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
2. Install the air pressure sensor together with the bracket with the 2 bolts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
3. Attach the wire harness clamp.
4. Connect the vacuum hose.
5. Connect the air pressure sensor connector.

INSTALL FAN AND GENERATOR V BELT

Text in Illustration
*1	Generator
*2	No. 1 Idler Pulley
*3	Vane Pump
*4	Fan Pulley
*5	Tensioner Pulley
*6	Crankshaft Pulley
*7	Idler Pulley
*8	Cooler Compressor

Install the fan and generator V belt to all the pulleys except the V-ribbed belt tensioner pulley.

Use the hexagon-shaped part indicated by the arrow in the illustration to move the tensioner pulley downward, and then install the fan and generator V belt to the tensioner pulley.
Note
- The backside of the fan and generator V belt should face the tensioner pulley.
- Check that the fan and generator V belt is properly installed to each pulley.

INSPECT FAN AND GENERATOR V BELT

Check the belt for wear, cracks or other signs of damage.

If any of the following defects is found, replace the fan and generator V belt.
- The belt is cracked.
- The belt is worn out to the extent that the cords are exposed.
- The belt has chunks missing from the ribs.
Text in Illustration

*a CORRECT

*b INCORRECT

Check that the belt fits properly in the ribbed grooves.

Tech Tips

Check with your hand to confirm that the belt has not slipped out of the grooves on the bottom of the pulley. If it has slipped out, replace the fan and generator V belt. Install a new fan and generator V belt correctly.

Text in Illustration
*a	CORRECT
*b	INCORRECT

Text in Illustration
*a	Bracket Side Indicator
*b	Arm Side Indicator
*c	Fan and Generator V Belt
*d	V-ribbed belt tensioner assembly

Check that the tensioner indicator mark is within range A shown in the illustration.

If the mark is not within range A, replace the fan and generator V belt.

Tech Tips

If a new belt has been installed, check that the tensioner indicator mark is within range A.

INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY
1. Install the engine service hole cover sub-assembly with the 5 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
INSTALL FRONT DOOR SCUFF PLATE RH
INSTALL FRONT SEAT ASSEMBLY RH

Click here
INSPECT FOR OIL LEAK
1. Start the engine. Make sure that there are no oil leaks from the areas that were worked on.
INSPECT ENGINE OIL LEVEL
1. Warm up the engine, stop the engine and wait 5 minutes.
2. Check that the oil level is between the dipstick low level mark and full level mark.
  
  If the level is low, check for leakage and add oil up to the full level mark.
  
  Note
  
  Do not fill with engine oil above the full level mark.
  
  Tech Tips
  
  A certain amount of engine oil will be consumed while driving. In the following situations, oil consumption may increase, and engine oil may need to be refilled in between oil maintenance intervals.
  - When the engine is new, for example directly after purchasing the vehicle or after replacing the engine.
  - If low quality oil or oil of an inappropriate viscosity is used.
  - When driving at high engine speed or with a heavy load, (when towing, or), when driving while accelerating or decelerating frequently.
  - When leaving the idling for a long time, or when driving frequently through heavy traffic.
  When judging the amount of oil consumption, keep in mind that the oil may have become diluted, making it difficult to judge the true level accurately.
INSPECT FOR COOLANT LEAKS

CAUTION:

Do not remove the radiator reservoir cap sub-assembly while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
1. Remove the radiator reservoir cap sub-assembly.
2. Fill the radiator reservoir assembly with engine coolant, and then attach a radiator cap tester.
3. Warm up the engine.
4. Using the radiator cap tester, increase the pressure inside the radiator to 137 kPa (1.4 kgf/cm², 20 psi), and then check that the pressure does not drop.
  
  If the pressure drops, check the hoses, radiator assembly and engine water pump assembly for leakage.
  
  If there are no signs or traces of external engine coolant leakage, check the heater core, cylinder block assembly and cylinder head sub-assembly.
5. Install the radiator reservoir cap sub-assembly.

INSPECT IGNITION TIMING

Warm up and stop the engine.

Note

A warmed up engine should have an engine coolant temperature of over 80°C (176°F), have an engine oil temperature of 60°C (140°F), and the engine speed should be stabilized.
When using the intelligent tester:
1. Connect the intelligent tester to the DLC3.
2. Start the engine and idle it.
3. Turn the intelligent tester main switch on.
4. Enter the following menus:
  
  Powertrain / Engine and ECT / Data List / IGN Advance
  
  Standard ignition timing
  
  5 to 15° BTDC at idle
  
  Note
  
  When checking the ignition timing, the transmission should be in neutral or park.
  
  Tech Tips
  
  Refer to the intelligent tester operator's manual for further detail.

Standard ignition timing
5 to 15° BTDC at idle

When not using the intelligent tester:

Connect the tester probe of a timing light to the wire of the ignition coil connector for the No.4 cylinder.
Note
- Use a timing light that detects primary signals.
- After checking, be sure to wrap the wire harness with tape.
Start the engine and idle it.

Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.

SST: 09843-18040

Text in Illustration
*a	Front view of DLC3

Note

Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.
When checking the ignition timing, the transmission should be in neutral or park.

Tech Tips

After connecting terminals (TC and CG), engine speed changes to approximately 1000 to 1500 rpm for 5 seconds, and then returns to idle speed. This is because the ECM checks that the ISC (idle speed control system) operates properly.
Perform the inspection of the ignition timing after engine speed is returned to idle speed.

Text in Illustration
*a	Engine Speed
*b	Approx. 1000 to 1500 rpm
*c	5 sec.
*d	Idle Speed
*e	Connect Terminals TC and CG

Inspect the ignition timing

Standard ignition timing

3 to 7° BTDC at idle
Disconnect terminals 13 (TC) and 4 (CG) of the DLC3.
Inspect the ignition timing

Standard ignition timing

5 to 15° BTDC at idle
Check that the ignition timing advances immediately when the engine speed is increased.
Turn the ignition switch off.
Remove the timing light.

INSPECT ENGINE IDLE SPEED
1. Warm up and stop the engine.
2. When using the intelligent tester:
  1. Connect the intelligent tester to the DLC3.
    
    Tech Tips
    
    Refer to the intelligent tester operator's manual for further details.
  2. Start the engine and idle it.
  3. Turn the intelligent tester main switch on.
  4. Enter the following menus:
    
    Powertrain / Engine and ECT / Data List / Engine SPD
    
    Idle speed
    
    650 to 750 rpm
    Note
    - When checking the idle speed, the transmission should be in the neutral position.
    - Switch off all accessories and air conditioning before connecting the intelligent tester.
  5. Turn the ignition switch off.
  6. Disconnect the intelligent tester from the DLC3.
3. Text in Illustration
  
  *a Front view of DLC3
  
  When not using the intelligent tester:
  1. Install SST to terminal 9 (TAC) of DLC3, and then connect a tachometer.
    
    SST
    
    09843-18030
    
    Note
    
    Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.
  2. Start the engine and idle it.
  3. Inspect the engine idling speed.
    
    Idle speed
    
    650 to 750 rpm
  4. Turn the ignition switch off.
  5. Disconnect the tachometer.
  6. Remove SST from terminal 9 (TAC).

Standard ignition timing
3 to 7° BTDC at idle

Standard ignition timing
5 to 15° BTDC at idle

Idle speed
650 to 750 rpm

Idle speed
650 to 750 rpm

INSPECT CO/HC

Start and warm up the engine.
Run the engine at 2500 rpm for approximately 180 seconds.
Insert the CO/HC meter testing probe at least 40 cm (1.31 ft.) into the tailpipe while idling.
Immediately check the CO/HC concentration at idle and at 2500 rpm.
Tech Tips
- When performing the 2-mode (2500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations.
- If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below.

If the CO/HC concentration is not as specified, perform troubleshooting in the order given below.

Check the air fuel ratio sensor Click here and heated oxygen sensor Click here operation.

See the table below for possible causes, and then inspect and repair the applicable causes if necessary.

CO	HC	Problems	Causes
Normal	High	Rough idle	Faulty ignitions: Incorrect timing Fouled, shorted or improperly gapped plugs Incorrect valve clearance Leaks in intake and exhaust valves Leaks in cylinders
Low	High	Rough idle (Fluctuating HC reading)	Vacuum leaks: PCV hoses Intake manifold Throttle body Brake booster line Lean mixture causing misfire
High	High	Rough idle (Black smoke from exhaust)	Restricted air filter Plugged PCV valve Faulty SFI systems: Faulty pressure regulator Defective engine coolant temperature sensor Defective mass air flow meter Faulty ECM Faulty injectors Faulty throttle body

Problems

Causes

Normal

High

Rough idle

Faulty ignitions:

Incorrect timing
Fouled, shorted or improperly gapped plugs

Incorrect valve clearance
Leaks in intake and exhaust valves
Leaks in cylinders

Low

High

Rough idle

(Fluctuating HC reading)

Vacuum leaks:

PCV hoses
Intake manifold
Throttle body
Brake booster line

Lean mixture causing misfire

High

Rough idle

(Black smoke from exhaust)

Restricted air filter
Plugged PCV valve
Faulty SFI systems:

Faulty pressure regulator
Defective engine coolant temperature sensor
Defective mass air flow meter
Faulty ECM
Faulty injectors
Faulty throttle body