CAMSHAFT INSTALLATION

Tech Tips

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


  1. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01I37LE02
      Text in Illustration
      *1 Pin Hole
      *2 Knock Pin

      Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear.

    2. A01I5YTE11
      Text in Illustration
      *1 Camshaft Timing Gear
      *2 Flange
      *a INCORRECT
      *b CORRECT
      *c Clearance
      *d No Clearance

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

    3. Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear by hand.

      Note

      Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

    4. Check the lock of the camshaft timing gear.


      1. Make sure that the camshaft timing gear is locked.

        Note

        Be careful not to damage the camshaft.

    5. A01I60SE05

      Release the lock pin.

      Text in Illustration
      *1 Rubber
      *2 Vinyl Tape
      *3 Knock Pin
      *a Retard Side Path
      *b Advance Side Path
      *c Open
      *d Close

      1. Clean the camshaft journal with non-residue solvent.

      2. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

        Tech Tips

        There are 4 oil paths in the grooves of the camshaft. Plug three of the paths with pieces of rubber.

      3. Open a hole at port A shown in the illustration.

      4. A01I4Y6

        While applying approximately 200 kPa (2.0 kgf/ cm2, 29 psi) of air pressure to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

        CAUTION:

        Cover the paths with a piece of cloth when applying pressure to keep oil from spraying.

        Note

        Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

        Tech Tips


        • The camshaft timing gear assembly may be turned in the advance direction without applying any force.

        • If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.

    6. Check for smooth rotation.


      1. Turn the camshaft timing gear within its movable range (26.5 to 28.5°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly.

        Note

        Do not allow the camshaft timing gear assembly to lock.

        If it locks, release the lock pin again.

    7. Remove the vinyl tape and rubber pieces from the camshaft.

    8. Remove the bolt and camshaft timing gear.

  2. INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean the No. 2 camshaft bearing.

    2. A01I4PVE04
      Text in Illustration
      *1 Vernier Caliper

      Install the No. 2 camshaft bearing to the camshaft housing sub-assembly.

    3. Using a vernier caliper, measure the distance between the camshaft housing edge and the No. 2 camshaft bearing edge.

      Standard distance
      1.15 to 1.85 mm (0.0453 to 0.0728 in.)

  3. INSTALL NO. 1 CAMSHAFT BEARING


    1. Clean the No. 1 camshaft bearing.

    2. A01I391E02
      Text in Illustration
      *1 Vernier Caliper

      Install the No. 1 camshaft bearing to the No. 1 camshaft bearing cap.

    3. Using a vernier caliper, measure the distance between the No. 1 camshaft bearing cap edge and the No. 1 camshaft bearing edge.

      Standard dimension A - B or B - A
      0 to 0.7 mm (0 to 0.0276 in.)

  4. INSTALL OIL CONTROL VALVE FILTER


    1. A01I5W9

      Install the oil control valve filter to the No. 1 camshaft bearing cap.

  5. INSTALL CAMSHAFT TIMING SPROCKET


    1. Secure the camshaft in a vise by clamping the hexagonal part using aluminum plates.

      Note

      Do not damage the camshaft by tightening the vise excessively.

    2. A01I4SB

      Install the camshaft timing sprocket to the No. 2 camshaft with the bolt.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Note

      Do not damage the No. 2 camshaft or camshaft timing sprocket.

  6. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01I4GWE03
      Text in Illustration
      *a Timing Notch

      Turn the crankshaft pulley until its timing notch (groove) and the timing mark "0" of the timing chain cover are aligned.

  7. INSTALL NO. 2 CAMSHAFT


    1. A01I3HXE06
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Valve Lash Adjuster
      *3 Valve Stem Cap

      Make sure that the valve rocker arms are installed as shown in the illustration.

    2. Clean the camshaft journals.

    3. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.

    4. A01I4I4E02
      Text in Illustration
      *a Paint Mark
      *b Timing mark

      Hold up the chain and align the timing mark and the paint mark, and install the No. 2 camshaft.

      Tech Tips

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

  8. INSTALL CAMSHAFT


    1. A01I3HXE06
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Valve Lash Adjuster
      *3 Valve Stem Cap

      Make sure that the valve rocker arms are installed as shown in the illustration.

    2. Clean the camshaft journals.

    3. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.

    4. A01I3C0E02
      Text in Illustration
      *1 Knock Pin
      *a Approximately 17°

      Install the camshaft to the camshaft housing as shown in the illustration.

      Tech Tips

      Perform "Inspection After Repair" after replacing the camshaft Click here.

  9. INSTALL CAMSHAFT BEARING CAP


    1. A01I4Q2

      Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.

    2. A01I2D2E04

      Using several steps, uniformly tighten the 10 bolts in the sequence shown in the illustration.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }
    3. A01I36UE04

      Using several steps, uniformly tighten the 11 bolts in the sequence shown in the illustration.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

    4. Check the torque of each bolt again.

  10. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01I5BRE04
      Text in Illustration
      *1 Knock Pin Hole
      *2 Alignment Mark
      *a Advanced Position
      *b Retarded Position

      Check the camshaft timing gear position.

      Note


      • If the camshaft timing gear is set to the advanced position, do not let the camshaft timing gear rotate clockwise during installation.

      • If the camshaft timing gear has rotated to the most retarded position, make sure to release the lock pin and set the camshaft timing gear to the most advanced position before tightening the camshaft timing gear.

    2. A01I5UME02
      Text in Illustration
      *a Narrow
      *b Wide

      Install the camshaft timing gear as shown in the illustration.

    3. A01I2NQE02
      Text in Illustration
      *a Narrow
      *b Wide

      Turn the camshaft timing gear approximately 180° counterclockwise.

    4. A01I554E03
      Text in Illustration
      *a Paint Mark
      *b Timing mark

      Align the paint mark with the timing mark to install the chain.

    5. A01I37LE05
      Text in Illustration
      *1 Knock Pin
      *a Knock Pin Hole

      Align and attach the knock pin of the camshaft with the pin hole of the camshaft timing gear.

    6. A01I5YTE13
      Text in Illustration
      *1 Camshaft Timing Gear
      *a Camshaft Flange
      *b No Clearance

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

    7. Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear by hand.

      Note

      Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

    8. If the lock pin has not been released, release it.


      1. A01I421E02
        Text in Illustration
        *1 Adhesive Tape Sealing Area
        *a Make a Hole

        After cleaning and degreasing the intake side VVT oil hole on the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.

        Note

        Be sure to seal the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

      2. Make a hole in the adhesive tape covering the oil hole as shown in the illustration. (Procedure A)

      3. A01I3EO

        Apply approximately 200 kPa (2.0 kgf/ cm2, 29 psi) of air pressure to the hole made in procedure A to release the lock pin.

        Note


        • If air leaks out, reattach the adhesive tape.

        • Cover the oil hole with a piece of cloth when applying air pressure to prevent oil from spraying.

      4. Forcibly turn the camshaft timing gear in the advance direction (counterclockwise).

        Tech Tips

        Depending on the air pressure applied, the camshaft timing gear may turn in the advance direction without assistance by hand.

      5. Remove the adhesive tape from the No. 1 camshaft bearing cap.

    9. A01I2JHE02
      Text in Illustration
      *a Hold
      *b Turn

      Using a wrench to hold the hexagonal portion of the camshaft, install the bolt.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Note

      Be careful not to damage the cylinder head or spark plug tube with the wrench.

    10. A01I5OSE02
      Text in Illustration
      *a Paint Mark
      *b Timing Mark

      Check that each timing mark of the camshaft timing gear and camshaft timing sprocket are aligned with each timing mark located as shown in the illustration.

      Tech Tips

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

  11. ADD ENGINE OIL


    1. A01I4SO

      Add 50 cc (3.1 cu. in.) of engine oil into the oil hole shown in the illustration.

      Note


      • Oil must be added if the valve lash adjuster assemblies were removed.

      • Make sure that the low pressure chamber and oil paths of the valve lash adjuster assemblies are full of engine oil.

  12. INSTALL TIMING CHAIN GUIDE


    1. Install the timing chain guide with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  13. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01I5W1E02

      Turn the crankshaft approximately 10° clockwise.

    2. Install a new gasket and the No. 1 chain tensioner assembly with the 2 bolts.

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

      Note

      Make sure not to drop the gasket inside the timing chain cover.

    3. Remove the pin from the stopper plate.

  14. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01I4JNE03
      Text in Illustration
      *a Approximately 7°
      *b Approximately 32°
      *c Timing Mark
      *d Timing Notch

      Turn the crankshaft pulley until its timing notch (groove) and the timing mark "0" of the timing chain cover are aligned.

    2. Check that the timing marks of the camshaft timing gears are as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration.

      Tech Tips

      "A" is not a timing mark.

  15. INSTALL TIMING CHAIN COVER PLATE


    1. Install a new gasket and the timing chain cover plate with the 4 bolts.

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

  16. INSTALL OIL PUMP RELIEF VALVE PLUG


    1. A01I4W8

      Using a 14 mm hexagon wrench, install a new gasket and the oil pump relief valve plug.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  17. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01I4QT

      Apply a light coat of engine oil to 2 new gaskets.

    2. Install the 2 gaskets to the camshaft bearing caps.

    3. Install a new gasket to the cylinder head cover sub-assembly.

      Note

      Remove any oil from the contact surface.

    4. A01I52AE01
      Text in Illustration
      *1 Seal Packing
      *2 Timing Chain Cover
      *3 Camshaft Housing

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.0 to 6.0 mm (0.118 to 0.236 in.)
      Application width A
      5.0 mm (0.197 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder head cover within 3 minutes after applying seal packing.

    5. A01I423E01

      Align the cylinder head cover with pin A. Then align the cylinder head cover with pin B and install the cylinder head cover sub-assembly.

    6. Install 3 new seal washers and the 16 bolts, and then tighten the bolts in the order shown in the illustration.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

      Note

      Do not apply oil for at least 2 hours after the installation.

  18. INSTALL IGNITION COIL ASSEMBLY


    1. Install the 4 ignition coil assemblies with the 4 bolts.

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

      Tech Tips

      Perform "Inspection After Repair" after replacing the ignition coil assembly Click here.

    2. Connect the 4 ignition coil assembly connectors.

  19. CONNECT ENGINE WIRE


    1. Install the engine wire to the engine with the 5 bolts and 3 nuts.

      A01I491E03
      Text in Illustration
      *1 Nut - -
      Torque:
      Bolt A
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Bolt B
      10.0 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Nut
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Connect the 8 connectors and 2 harness clamps.

  20. INSTALL NO. 2 ENGINE ROOM RELAY BLOCK


    1. Install the No. 2 engine room relay block with the bolt and harness clamp.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Install the front fender liner RH with the screw.

  21. INSTALL INVERTER RESERVE TANK ASSEMBLY


    1. A01I5YQE01

      Temporarily install the inverter reserve tank assembly with the 2 bolts.

    2. Tighten the 2 bolts to the inverter reserve tank assembly in the order of the bolt A and bolt B.

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

  22. INSTALL ENGINE MOVING CONTROL ROD BRACKET


    1. When the engine moving control rod has been replaced.


      1. A01I298

        Temporarily install the engine moving control rod bracket with the 4 bolts.

      2. Fully tighten the 4 bolts.

        Torque:
        38 N*m  { 387 kgf*cm, 28 ft.*lbf }
      3. A01I5J4E01
        Text in Illustration
        *a Torque Wrench Fulcrum Length

        Using SST, fully tighten the bolt.

        SST
        09961-00950
        Torque:
        Specified tightening torque
        52 N*m  { 530 kgf*cm, 38 ft.*lbf }

        Tech Tips


        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.

        • When using SST (fulcrum length of 150 mm (5.91 in.)) + torque wrench (fulcrum length of 260 mm (10.2 in.)):

          33 N*m (337 kgf*cm, 24 ft.*lbf)

    2. A01I298

      When the engine moving control rod has been reused.


      1. Temporarily install the engine moving control bracket with the 4 bolts.

      2. Fully tighten the 4 bolts.

        Torque:
        38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  23. INSTALL EARTH WIRE


    1. Install the earth wire to the engine moving control rod bracket with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  24. INSTALL NO. 2 ENGINE MOUNTING STAY RH


    1. Install the No. 2 engine mounting stay RH with the 2 bolts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  25. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. A01I575E03
      Text in Illustration
      *a Projection

      Insert the projection of the air cleaner case sub-assembly into the hole of the No. 2 air cleaner bracket as shown in the illustration.

    2. Tighten the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  26. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. Install the air cleaner filter element sub-assembly.

      Note

      Install the air cleaner filter element sub-assembly with the printed side facing the vehicle front.

  27. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. Install the air cleaner hose with the hose clamp.

    2. A01I3I7E01
      Text in Illustration
      *1 Retainer
      *a Push

      Connect the 2 fuel vapor feed hoses.

      Note


      • Check that there are no scratches or foreign matter around the connected part of the fuel tube connector and pipe before performing this work.

      • Connect the quick connector and push the retainer in until the retainer makes a "click" sound to lock the claws of the retainer.

      • After connecting the fuel vapor feed hose to the fuel tube connector, check that the fuel vapor feed hose is securely connected by pulling on the fuel tube connector and the fuel vapor feed hose.

    3. A01I3I9E01
      Text in Illustration
      *a Hinge
      *b Clamp

      Connect the 2 hinges of the air cleaner cap subassembly.

    4. Install the air cleaner cap sub-assembly with the 2 clamps.

    5. Connect the wire harness clamp and connector.

    6. Connect the ventilation hose to the cylinder head cover.

    7. Connect the mass air flow meter connector and wire harness clamp to the air cleaner cap sub-assembly.

  28. INSTALL INLET AIR CLEANER ASSEMBLY


    1. Install the inlet air cleaner assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  29. INSPECT FOR OIL LEAK

  30. INSTALL FRONT FENDER APRON SEAL RH

  31. INSTALL ENGINE UNDER COVER RH

  32. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

  33. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. Engage the 3 pins and install the No. 1 engine cover sub-assembly.

  34. INSTALL COOL AIR INTAKE DUCT SEAL


    1. Install the cool air intake duct seal with the 9 clips.

  35. INSTALL FRONT WHEEL RH

    Torque:
    103 N*m  { 1049 kgf*cm, 76 ft.*lbf }