CAMSHAFT INSTALLATION

CAUTION / NOTICE / HINT

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

    Replaced Parts (A) Pipes Requiring New Replacement
    Injector assembly (including shuffling the injector assemblies between the cylinders)

    • No. 1 injection pipe sub-assembly

    • No. 1 injection pipe sub-assembly
    Supply pump assembly Fuel inlet pipe sub-assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing chain case assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Fuel inlet pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

  • The injector assembly is a precision instrument. Do not use the injector assembly if it is struck or dropped.

  • The supply pump assembly is a precision instrument. Do not use the supply pump assembly if it is struck or dropped.

  • Hold the supply pump assembly itself during removal and installation. Do not hold the pre-stroke control valve or fuel pipe, etc.

  • Make sure foreign matter does not enter the fuel path.

PROCEDURE


  1. INSTALL CAMSHAFT


    1. B001CVLE01
      Text in Illustration
      *1 Valve Rocker Arm Sub-assembly
      *2 Valve Stem Cap
      *3 Valve Lash Adjuster Assembly

      Check that the valve rocker arm sub-assembly is firmly set to the valve lash adjuster assembly.

    2. Apply a light coat of engine oil to the camshaft journals of the cylinder head sub-assembly and the thrust portion of the camshaft.

    3. B001FFBE02
      Text in Illustration
      *a Paint Mark
      *b Timing Mark

      Align the paint mark of the No. 2 chain sub-assembly and timing mark of the camshaft timing sprocket, and install the camshaft timing sprocket to the No. 2 chain sub-assembly.

      Tech Tips

      Make sure the timing mark of the camshaft timing sprocket face the front side.

    4. B001F92

      Align the knock pin of the No. 1 camshaft to the groove of the sprocket and install the No. 1 camshaft to the camshaft timing sprocket, and set the bolt.

    5. B001H6UE02
      Text in Illustration
      *a Paint Mark
      *b Timing Mark

      Align the paint mark of the No. 2 chain sub-assembly and timing mark of the camshaft timing sprocket, and install the camshaft timing sprocket to the No. 2 chain sub-assembly.

      Tech Tips

      Make sure the timing mark of the camshaft timing sprocket face the front side.

    6. B001CG4

      Align the knock pin of the No. 2 camshaft to the groove of the sprocket and install the No. 2 camshaft to the camshaft timing sprocket, and set the bolt.

      Tech Tips

      Glove is at the rear end of the No. 2 camshaft.

      B001GQVE02
      Text in Illustration
      *a Glove
    7. B001IGLE02
      Text in Illustration
      *a Paint Mark
      *b Timing Mark

      Check the timing mark of the camshaft timing sprocket and the paint mark of the No. 2 chain sub-assembly.

    8. B001ID9

      Set the No. 1 camshaft bearing cap and 8 No. 2 camshaft bearing caps to the cylinder head sub-assembly as shown in the illustration.

    9. Temporarily install the 20 bolts.

    10. B001EY8E02

      Uniformly tighten the 20 bolts in several steps in the order shown in the illustration.

      Torque:
      for bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for bolt B
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Text in Illustration
      B001CHY Bolt A
      B001DEF Bolt B
    11. B001HJCE02
      Text in Illustration
      *1 No. 1 Camshaft
      *2 No. 2 Camshaft

      Hold the hexagonal portion of the No. 1 camshaft and No. 2 camshaft with a wrench, and tighten the 2 bolts.

      Torque:
      81 N*m  { 826 kgf*cm, 60 ft.*lbf }

      Note

      Be careful not to damage the cylinder head sub-assembly with the wrench.

    12. Remove the pin from the No. 2 chain tensioner assembly.

    13. Install a new gasket and the oil pump relief valve plug to the timing chain cover.

      Torque:
      46 N*m  { 469 kgf*cm, 34 ft.*lbf }

    14. Clean and degrease the contact surfaces of the cylinder head sub-assembly and No. 3 camshaft bearing cap.

    15. B001GWEE02
      Text in Illustration
      *a Engine Front
      *b Seal Packing

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

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.0 mm (0.118 in.)

      Note


      • Do not allow seal packing to contact the oil passage of the No. 3 camshaft bearing cap.

      • After applying seal packing, install the No. 3 camshaft bearing cap within 3 minutes and tighten the bolts within 10 minutes.

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

    16. Install the No. 3 camshaft bearing cap with the 2 bolts.

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

    17. Wipe off excess seal packing from between No. 3 camshaft bearing cap and cylinder head sub-assembly.

  2. INSTALL TIMING CHAIN GUIDE


    1. Install the timing chain guide to the cylinder head sub-assembly with the bolt.

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

  3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  4. INSTALL NOZZLE HOLDER GASKET

    Click here

  5. TEMPORARILY INSTALL INJECTOR ASSEMBLY

    Click here

  6. TEMPORARILY INSTALL NO. 1 INJECTION PIPE SUB-ASSEMBLY AND NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Click here

  7. TIGHTEN INJECTOR ASSEMBLY

    Click here

  8. TIGHTEN NO. 1 INJECTION PIPE SUB-ASSEMBLY AND NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Click here

  9. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  10. INSTALL HARNESS BRACKET

    Click here

  11. INSTALL WIRING HARNESS CLAMP BRACKET

    Click here

  12. INSTALL INSTALL NO. 1 EGR COOLER WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  13. INSTALL VACUUM CONTROL VALVE SET

    Click here

  14. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

    Click here

  15. CONNECT NO. 4 WATER BY-PASS PIPE SUB-ASSEMBLY

    Click here

  16. INSTALL NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY

    Click here

  17. INSTALL NO. 2 EGR PIPE

    Click here

  18. INSTALL EGR VALVE BRACKET

    Click here

  19. INSTALL TURBO PRESSURE SENSOR

    Click here

  20. INSTALL GAS FILTER

    Click here

  21. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Click here

  22. INSTALL AIR TUBE ASSEMBLY

    Click here

  23. INSTALL ENGINE COVER BRACKET

    Click here

  24. INSTALL PIPE CLAMP

    Click here

  25. TEMPORARILY INSTALL NO. 2 VACUUM PIPE

    Click here

  26. TEMPORARILY INSTALL NO. 1 VACUUM PIPE

    Click here

  27. TIGHTEN NO. 2 VACUUM PIPE

    Click here

  28. TIGHTEN NO. 1 VACUUM PIPE

    Click here

  29. INSTALL EXHAUST GAS TEMPERATURE SENSOR

    Click here

  30. INSTALL DIFFERENTIAL PRESSURE SENSOR

    Click here

  31. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  32. INSTALL NO. 1 INJECTOR HOLDER

    Click here

  33. CONNECT NO. 5 WATER BY-PASS HOSE

    Click here

  34. CONNECT NO. 4 WATER BY-PASS HOSE

    Click here

  35. INSTALL VENTILATION PIPE SUB-ASSEMBLY

    Click here

  36. INSTALL NO. 1 FUEL PIPE

    Click here

  37. INSTALL NO. 2 ENGINE COVER BRACKET

    Click here

  38. INSTALL NO. 3 ENGINE COVER BRACKET

    Click here

  39. INSTALL NO. 2 WATER BY-PASS PIPE

    Click here

  40. INSTALL WATER HOSE SUB-ASSEMBLY

    Click here

  41. INSTALL CAMSHAFT OIL SEAL RETAINER

    Click here

  42. INSTALL VACUUM PUMP ASSEMBLY

    Click here

  43. INSTALL ENGINE ASSEMBLY

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