CAMSHAFT INSTALLATION

Tech Tips

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


  1. INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean the No. 2 camshaft bearing.

    2. Install the camshaft bearing to the camshaft housing.

    3. B000M4XE04
      Text in Illustration
      *1 Vernier Caliper

      Using a vernier caliper, measure the distance between the camshaft housing edge and the camshaft bearing edge.

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

  2. INSTALL NO. 1 CAMSHAFT BEARING


    1. B000NIZE03
      Text in Illustration
      *1 Vernier Caliper

      Clean the No. 1 camshaft bearing.

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

    3. Using a vernier caliper, measure the distance between the camshaft bearing cap edge and the camshaft bearing edge.

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

  3. INSTALL OIL CONTROL VALVE FILTER


    1. B000KN8

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

  4. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. B000KC4E10
      Text in Illustration
      *a Knock 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.

    2. B000JOZE33
      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. B000NQT

      Fix the camshaft timing exhaust gear assembly with the bolt.

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

      Note

      Do not disassemble the camshaft timing exhaust gear assembly.

      Tech Tips

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

  5. SET TDC/COMPRESSION


    1. B000J7SE02
      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 sub-assembly are aligned.

  6. INSTALL NO. 2 CAMSHAFT


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

      B000L31E01
      Text in Illustration
      *A Type A *B Type B
      *1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap - -

    2. Clean the camshaft journals.

    3. Apply a light coat of engine oil to the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.

    4. B000LM4E02
      Text in Illustration
      *a Paint Mark
      *b Timing Mark

      Hold up the chain sub-assembly 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.

  7. INSTALL CAMSHAFT


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

      B000L31E01
      Text in Illustration
      *A Type A *B Type B
      *1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap - -

    2. Clean the camshaft journals.

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

    4. B000IXLE02
      Text in Illustration
      *a Approximately 17°
      *b Knock Pin

      Install the camshaft to the camshaft housing sub-assembly as shown in the illustration.

      Tech Tips

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

  8. INSTALL CAMSHAFT BEARING CAP


    1. B000MJW

      Confirm the marks and numbers on the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and 3 No. 3 camshaft bearing caps and place them in their proper positions and directions.

    2. B000M7DE02

      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. B000MJGE02

      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.

  9. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. B000K6UE05
      Text in Illustration
      *a Advanced Position
      *b Retarded Position
      *c Knock Pin Hole
      *d Alignment Mark

      Check the camshaft timing gear assembly position.

      Note


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

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

    2. B000JOWE01
      Text in Illustration
      *a Narrow
      *b Wide

      Install the camshaft timing gear assembly as shown in the illustration.

    3. B000HEFE01
      Text in Illustration
      *a Narrow
      *b Wide

      Turn the camshaft timing gear assembly approximately 180° counterclockwise.

    4. B000GZIE03
      Text in Illustration
      *a Paint Mark
      *b Timing Mark

      Align the paint mark with the timing mark to install the chain sub-assembly.

      Tech Tips

      "A" is not a timing mark.

    5. B000HFGE16
      Text in Illustration
      *a Knock Pin Hole
      *b Knock Pin

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

    6. B000JOZE33
      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.

    7. Secure the camshaft in place by hand, and then temporarily install the installation bolt to the camshaft timing gear assembly 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. B000LOME02
        Text in Illustration
        *a Make a Hole
        *b Adhesive Tape Sealing Area

        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. B000HUN

        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 assembly in the advance direction (counterclockwise).

        Tech Tips

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

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

    9. B000K3X

      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 cylinder head sub-assembly or spark plug tube with the wrench.

    10. B000KRME01
      Text in Illustration
      *a Paint Mark
      *b Timing Mark

      Check that both timing marks on the camshaft timing gear assembly and camshaft timing exhaust gear assembly are facing upward as shown in the illustration.

      Tech Tips


      • "A" is not a timing mark.

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

  10. ADD ENGINE OIL


    1. B000N6C

      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.

  11. INSTALL TIMING CHAIN GUIDE


    1. Install the timing chain guide with the bolt.

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

  12. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B000IZTE01

      Turn the crankshaft pulley approximately 10° clockwise.

    2. B000H26

      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 sub-assembly.

    3. Remove the pin from the stopper plate.

  13. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


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

      B000L0IE01
      Text in Illustration
      *a Timing Mark *b Timing Notch
      *c Approximately 7° *d Approximately 32°

    2. Check that both timing marks on the camshaft timing gear assembly and camshaft timing exhaust gear assembly are facing upward 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.

  14. INSTALL TIMING CHAIN COVER PLATE


    1. B000MHS

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

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

  15. INSTALL TIMING CHAIN COVER TIGHT PLUG


    1. B000IJD

      Using a 14 mm hexagon wrench, install a new gasket and the plug.

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

  16. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B000NHO

      Apply a light coat of engine oil to 3 new gaskets.

    2. Install the 3 gaskets to the camshaft bearing caps.

    3. Install a new gasket to the cylinder head cover.

      Note

      Remove any oil from the contact surface.

    4. B000IK0E03
      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 and tighten the bolts within 15 minutes after applying seal packing.

    5. B000I28E01

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

    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 4 hours after the installation.

  17. 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.

  18. CONNECT ENGINE WIRE


    1. B000K2KE01

      Connect the engine wire to the engine assembly with the bolts and nuts.

      Torque:
      Nut (A)
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
      Nut (B)
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Connect the connectors and clamps.

  19. INSTALL NO. 2 ENGINE ROOM RELAY BLOCK (w/ No. 2 Engine Room Relay Block)


    1. Engage the 2 clamps and install the No. 2 engine room relay block with the bolt.

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

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

  20. INSTALL ENGINE MOVING CONTROL ROD BRACKET

  21. INSTALL EARTH WIRE

  22. INSTALL NO. 2 ENGINE MOUNTING STAY RH

  23. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

  24. INSTALL AIR CLEANER FILTER ELEMENT

  25. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


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

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

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

    4. Install the fuel vapor feed hose to the air cleaner hose.

    5. Connect the mass air flow meter connector and 2 wire harness clamps to the air cleaner cap sub-assembly.

    6. Connect the vacuum switching valve assembly to the air cleaner hose.

  26. INSTALL INLET AIR CLEANER ASSEMBLY

  27. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  28. INSPECT FOR OIL LEAK

  29. INSTALL FRONT FENDER APRON SEAL RH

  30. INSTALL ENGINE UNDER COVER RH

  31. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

  32. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

  33. INSTALL COOL AIR INTAKE DUCT SEAL (for TMC, TMMR Made)

  34. INSTALL COOL AIR INTAKE DUCT SEAL (for TMMK Made)


    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 }