CAMSHAFT INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

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


PROCEDURE


  1. INSTALL VALVE LASH ADJUSTER ASSEMBLY

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  2. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

    Click here

  3. INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean the No. 2 camshaft bearing.

      Note

      Do not apply engine oil to the No. 2 camshaft bearing or contact surfaces.

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

    3. A000PKBE03
      Text in Illustration
      *1 Camshaft Housing Sub-assembly
      *2 No. 2 Camshaft Bearing
      *a Vernier Caliper

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

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

  4. INSTALL NO. 2 CAMSHAFT

    Tech Tips

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



    1. Clean the No. 2 camshaft journals and camshaft housing sub-assembly.

    2. Apply a light coat of engine oil to the No. 2 camshaft journals and camshaft housing sub-assembly.

    3. Set the No. 2 camshaft to the camshaft housing sub-assembly.

  5. INSTALL CAMSHAFT

    Tech Tips

    Perform "Inspection After Repair" after replacing the camshaft.



    1. Clean the camshaft journals and camshaft housing sub-assembly.

    2. Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly.

    3. Set the camshaft to the camshaft housing sub-assembly.

  6. INSTALL NO. 1 CAMSHAFT BEARING


    1. Clean the No. 1 camshaft bearing.

      Note

      Do not apply engine oil to the No. 1 camshaft bearing or contact surfaces.

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

    3. A000QM4E03
      Text in Illustration
      *1 No. 1 Camshaft Bearing Cap
      *2 No. 1 Camshaft Bearing
      *a Vernier Caliper

      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.)

  7. INSTALL OIL CONTROL VALVE FILTER


    1. Check that there is no foreign matter on the mesh section.

    2. A000P76

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

      Note

      Do not touch the mesh section on the oil control valve filter.

  8. INSTALL CAMSHAFT BEARING CAP


    1. Clean the camshaft bearing caps.

    2. Apply a light coat of engine oil to the camshaft journals and camshaft bearing caps.

    3. Install the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap.

    4. A000N57E04
      Text in Illustration
      *1 No. 1 camshaft bearing cap
      *2 No. 2 camshaft bearing cap
      *3 No. 3 camshaft bearing cap
      *4 No. 4 camshaft bearing cap

      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 }

      Note

      After installing the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap, make sure that the camshaft and No. 2 camshaft rotate smoothly.

  9. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A000QQBE02
      Text in Illustration
      *a Seal Packing

      Apply seal packing in a continuous line as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.0 to 4.0 mm (0.118 to 0.157 in.)

      Note


      • Remove any oil from the contact surface.

      • Check the bolts and bolt holes and clean them.

      • Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

      • Do not add engine oil within 2 hours of installation.

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

    2. A000RIPE09
      Text in Illustration
      *a Approximately 17°
      *b Approximately 2°
      *c Knock Pin

      Position the knock pin of the camshaft and No. 2 camshaft as shown in the illustration.

    3. A000PH3E02
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap

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

    4. A000SYNE01

      Install the camshaft housing sub-assembly, and then tighten the 20 bolts in the order shown in the illustration.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }
      Standard Bolt
      Item Length
      Bolt A 70 mm (2.76 in.)
      Bolt B 45 mm (1.77 in.)
      Text in Illustration
      B002B6O Bolt A
      B002BBR Bolt B

      Note

      If the bolts have been loosened during the installation, apply seal packing black to the camshaft housing sub-assembly again.

  10. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

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  11. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    Tech Tips

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



    1. When using a new camshaft timing gear assembly:


      1. A000P7SE03
        Text in Illustration
        *a Lock Pin Released
        *b Lock Pin Locked
        *c Pin Hole
        *d Lock Check Point

        Check that the camshaft timing gear assembly is not locked.

        Note

        If locked, release the lock pin of the camshaft timing gear assembly Click here.

    2. A000R0YE03
      Text in Illustration
      *a Pin Hole
      *b Knock Pin

      When reusing the camshaft timing gear assembly:


      1. Release the lock pin Click here.

    3. Put the camshaft timing gear assembly and camshaft together by aligning the pin hole and knock pin.

    4. Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the knock pin enters the pin hole.

      Note


      • Be sure not to turn the camshaft timing gear assembly in the advanced direction.

      • Do not forcefully press the camshaft timing gear assembly. Otherwise, the tip of knock pin of the camshaft may damage the seal surface of the camshaft timing gear assembly, leading to poor sealing.

    5. A000RP1E50
      Text in Illustration
      *1 Camshaft Timing Gear Assembly
      *a Incorrect
      *b Correct
      *c Clearance
      *d No Clearance
      *e Camshaft Flange

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

    6. A000T5RE02
      Text in Illustration
      *a Hold
      *b Turn

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

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

      Note


      • Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.

      • If the camshaft timing gear assembly has been locked at the most retarded position, release the lock pin first, and then tighten the bolt.

      • The lock pin may be damaged if the bolt is tightened when the camshaft timing gear assembly is locked.

  12. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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  13. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Tech Tips

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



    1. A000RF2E15
      Text in Illustration
      *a Pin Hole
      *b Knock Pin

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

      Note

      Do not forcefully press the camshaft timing exhaust gear assembly. Otherwise, the tip of knock pin of the No. 2 camshaft may damage the seal surface of the camshaft timing exhaust gear assembly, leading to poor sealing.

    2. A000RP1E50
      Text in Illustration
      *1 Camshaft Timing Exhaust Gear Assembly
      *a Incorrect
      *b Correct
      *c Clearance
      *d No Clearance
      *e Camshaft Flange

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

    3. A000RABE02
      Text in Illustration
      *a Hold
      *b Turn

      Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the bolt.

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

      Note

      Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.

  14. POUR ENGINE OIL

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  15. INSTALL NO. 1 CHAIN VIBRATION DAMPER

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  16. INSTALL CHAIN SUB-ASSEMBLY

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  17. INSTALL CHAIN TENSIONER SLIPPER

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  18. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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  19. INSTALL TIMING CHAIN GUIDE

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  20. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

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  21. INSTALL TIMING CHAIN COVER ASSEMBLY

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