CAMSHAFT INSTALLATION

CAUTION / NOTICE / HINT

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.

PROCEDURE


  1. INSTALL CAMSHAFT


    1. B001E8KE02
      Text in Illustration
      *1 Key

      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 prevent the top of the piston from hitting against the valve head.

    2. B001IF7E04

      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.

        Text in Illustration
        *1 Key Groove
        *a Upward
      3. B001H6I

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

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

    4. B001E1ZE05

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

      Text in Illustration
      *1 Seal Packing
      *2 Oil Passage
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      4 mm (0.157 in.)

      Note


      • Do not allow seal packing to contact the oil passage of the bearing cap.

      • After applying seal packing, 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 installation.


      1. B001DWL

        Install the 5 bearing caps to their proper locations.

      2. B001H4HE05

        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 }
    5. B001F5WE02

      Install a new camshaft oil seal.


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

      2. Using SST and a hammer, tap in the oil seal until its surface is flush with the surfaces of the camshaft bearing cap and cylinder head.

        SST
        09608-06041

  2. INSTALL NO. 2 TIMING BELT COVER

    Click here

  3. INSTALL CAMSHAFT TIMING PULLEY

    Click here

  4. INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY

    Click here

  5. INSTALL TIMING BELT

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  6. INSPECT AND ADJUST VALVE CLEARANCE

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  7. INSTALL NO. 1 TIMING BELT COVER

    Click here

  8. INSTALL FAN SHROUD

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  9. INSTALL NO. 1 RADIATOR HOSE

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  10. INSTALL INJECTOR ASSEMBLY

    Click here

  11. INSPECT FOR FUEL LEAK

    Click here

  12. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  13. INSTALL NOZZLE HOLDER SEAL

    Click here

  14. INSTALL VENTILATION PIPE

    Click here

  15. INSTALL NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  16. INSTALL WIRE HARNESS

  17. INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  18. INSTALL NO. 4 INJECTION PIPE SUB-ASSEMBLY

    Click here

  19. INSTALL MANIFOLD STAY WITH VACUUM SWITCHING VALVE

    Click here

  20. INSTALL INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY (w/o EGR System)

    Click here

  21. CONNECT ENGINE WIRE (w/o EGR System)

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  22. INSTALL AIR CONNECTOR STAY (w/o EGR System)

    Click here

  23. INSTALL INJECTION PIPE (w/o EGR System)

    Click here

  24. INSTALL THROTTLE BODY BRACKET (w/o EGR System)

    Click here

  25. INSTALL NO. 2 EGR VALVE ASSEMBLY (w/ EGR System with EGR Cooler)

    Click here

  26. INSTALL EGR COOLER WITH PIPE (w/ EGR System with EGR Cooler)

    Click here

  27. TEMPORARILY INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System with EGR Cooler)

    Click here

  28. TIGHTEN ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System with EGR Cooler)

    Click here

  29. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY (w/ EGR System without EGR Cooler)

    Click here

  30. TEMPORARILY INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System without EGR Cooler)

    Click here

  31. TIGHTEN ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System without EGR Cooler)

    Click here

  32. INSTALL AIR CONNECTOR STAY (w/ EGR System)

    Click here

  33. INSTALL ELECTRIC VACUUM REGULATING VALVE ASSEMBLY (w/ EGR System)

    Click here

  34. INSTALL EGR VALVE BRACKET (w/ EGR System)

    Click here

  35. CONNECT ENGINE WIRE (for LHD)

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  36. CONNECT ENGINE WIRE (for RHD)

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  37. INSTALL INJECTION PIPE (w/ EGR System)

    Click here

  38. CONNECT NO. 4 WATER BY-PASS HOSE (w/ EGR System with EGR Cooler)

    Click here

  39. CONNECT NO. 3 WATER BY-PASS HOSE (w/ EGR System with EGR Cooler)

    Click here

  40. INSTALL DIESEL THROTTLE BODY ASSEMBLY (w/ EGR System)

    Click here

  41. INSTALL NO. 1 INTAKE PIPE

    Click here

  42. CONNECT NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY

    Click here

  43. CONNECT INLET HEATER WATER HOSE

    Click here

  44. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  45. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  46. BLEED AIR FROM FUEL SYSTEM

    Click here

  47. ADD ENGINE COOLANT

    Click here

  48. INSPECT FOR COOLANT LEAK

    Click here

  49. INSPECT FOR OIL LEAK

    Click here

  50. INSPECT FOR FUEL LEAK

    Click here

  51. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

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  52. INSTALL FRONT BUMPER LOWER COVER

    Click here

  53. INSPECT ENGINE OIL LEVEL

    Click here