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.

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PROCEDURE


  1. INSTALL VALVE LASH ADJUSTER ASSEMBLY

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

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  3. INSTALL CAMSHAFT


    1. Clean the camshaft journals.

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

    3. A01LWKT

      Install the camshaft to the camshaft housing sub-assembly.

      Tech Tips

      Perform "Inspection After Repair" after replacing the camshaft.

      Click here

  4. INSTALL NO. 2 CAMSHAFT


    1. Clean the No. 2 camshaft journals.

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

    3. A01M2RG

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

      Tech Tips

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

      Click here

  5. INSTALL CAMSHAFT BEARING CAP


    1. Apply engine oil to the camshaft bearing caps.

    2. Install the 5 camshaft bearing caps to the camshaft housing sub-assembly.

    3. A01LYV6C02
      *A Camshaft Bearing Cap Type A
      *B Camshaft Bearing Cap Type B

      Tighten the 5 bolts in the order shown in the illustration.

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

  6. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A01LZN9C01
      *A Type A
      *B Type B
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap

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

    2. A01LV8FC10
      *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
      Seal Diameter
      3.5 to 4.0 mm (0.138 to 0.157 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

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

    3. A01LVU7C03
      *a TDC
      *b Timing Mark

      Set the crankshaft in the position (40° BTDC) shown in the illustration.

      Note

      Turn the crankshaft clockwise when positioning the No. 1 cylinder after the camshaft housing sub-assembly is installed.

      Tech Tips

      Make sure that the timing mark of the crankshaft is positioned as shown in the illustration.

    4. Set the camshaft and No. 2 camshaft as shown in the illustration.

      A01LYFJC04
      *a Straight Pin - -

      Tech Tips

      Make sure that the straight pins of the camshaft and No. 2 camshaft are positioned as shown in the illustration.

    5. Install the camshaft housing sub-assembly and tighten the 18 bolts in the order shown in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Note


      • After installing the camshaft housing sub-assembly, make sure that the straight pins are positioned as shown in the illustration.

      • If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly, clean the installation surfaces, and reapply seal packing.

      • If the camshaft housing sub-assembly is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.

      • After installing the camshaft housing sub-assembly, wipe off any seal packing that seeped out from between the camshaft housing sub-assembly and the cylinder head sub-assembly.

  7. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. Check that the straight pin is installed on the camshaft.

    2. A01M2DKC18
      *a Key Groove
      *b Straight Pin

      Fit the camshaft timing gear assembly and camshaft together by aligning the key groove and straight pin.

      Note


      • Do not forcefully push in the camshaft timing gear assembly. This may cause the camshaft straight pin tip to damage the installation surface of the camshaft timing gear assembly.

      • Do not turn the camshaft timing gear assembly in the retard direction (clockwise).

    3. A01LVKUC10
      *a Hold

      Tighten the bolt with the camshaft timing gear assembly secured in place.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }
    4. A01M01OC09
      *a Lock

      Check that the camshaft timing gear assembly moves in the retard direction (clockwise) and locks in the most retarded position.

      Tech Tips

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

      Click here

  8. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. Check that the straight pin is installed on the No. 2 camshaft.

    2. A01M28ZC16
      *a Key Groove
      *b Straight Pin

      Fit the camshaft timing exhaust gear assembly and No. 2 camshaft together by aligning the key groove and straight pin.

      Note

      Do not forcefully push in the camshaft timing exhaust gear assembly. This may cause the No. 2 camshaft straight pin tip to damage the installation surface of the camshaft timing exhaust gear assembly.

    3. A01M0BRC09
      *a Hold

      Tighten the bolt with the camshaft timing exhaust gear assembly secured in place.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

    4. Make sure that the camshaft timing exhaust gear assembly is locked.

      Tech Tips

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

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  9. INSTALL TIMING CHAIN GUIDE


    1. Install the timing chain guide with the 2 bolts.

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

  10. INSTALL CHAIN SUB-ASSEMBLY


    1. A01M2O8C03
      *a TDC
      *b Timing Mark

      Set the crankshaft in the position (90° ATDC) shown in the illustration.

      Tech Tips

      Make sure that the timing mark of the crankshaft is positioned as shown in the illustration.

    2. Set the camshaft timing gear assembly and camshaft timing exhaust gear assembly in the positions (20° ATDC) shown in the illustration.

      A01M1GZC02
      *a TDC *b Timing Mark

    3. Set the crankshaft in the position (20° ATDC) shown in the illustration.

    4. Align the timing marks of the camshaft timing gear assembly, camshaft timing exhaust gear assembly and crankshaft with the mark plates of the chain sub-assembly and install the chain sub-assembly.

      A01M2C2C02
      *a Mark Plate (Orange) *b Mark Plate (Yellow)
      *c Timing Mark - -

  11. INSTALL TIMING CHAIN TENSION ARM


    1. Install the timing chain tension arm with the bolt.

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

  12. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    Tech Tips


    • There are 2 installation types for the No. 1 chain tensioner assembly.

    • Depending on the installation type, the number of bolts, nuts and stud bolts used will vary.


    1. for No. 1 chain tensioner assembly installed with nut:


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

      2. Install the No. 1 chain tensioner assembly with the 2 nuts.

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

    2. for No. 1 chain tensioner assembly installed with bolt:


      1. 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 }

    3. Install the No. 2 chain vibration damper with the 2 bolts.

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

    4. Remove the pin from the No. 1 chain tensioner assembly.

    5. Turn the crankshaft approximately 20° counterclockwise to set it to TDC. Make sure that the timing marks and mark plates are correctly positioned and that the chain sub-assembly is securely fit into the timing chain tension arm, timing chain guide and No. 2 chain vibration damper.

      A01LWJMC02
      *a TDC *b Turn
      *c Mark Plate (Orange) *d Mark Plate (Yellow)
      *e Timing Mark - -

  13. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

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