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

    3. B000M4XE06
      Text in Illustration
      *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
      1.15 to 1.85 mm (0.0453 to 0.0728 in.)

  2. INSTALL NO. 1 CAMSHAFT BEARING


    1. B000IOIE01
      Text in Illustration
      *a Vernier Caliper

      Clean the No. 1 camshaft bearing.

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

    3. Using a vernier caliper, measure the distance between the No. 1 camshaft bearing cap edge and the No. 1 camshaft bearing edge.

      Difference Between (A) and (B)
      0 to 0.7 mm (0 to 0.0276 in.)

  3. INSTALL OIL CONTROL VALVE FILTER


    1. B000JAM

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

  4. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. Secure the No. 2 camshaft in a vise by clamping the hexagonal part between aluminum plates.

      Note

      Do not damage the No. 2 camshaft by tightening the vise excessively.

    2. B000I6QE01
      Text in Illustration
      *a Knock Pin Hole
      *b Knock Pin

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

      Note

      Be careful not to damage the contact surface of the camshaft timing exhaust gear assembly with the knock pin of the No. 2 camshaft.

    3. B000N1XE01
      Text in Illustration
      *1 Camshaft Timing Exhaust Gear Assembly
      *a Incorrect
      *b Correct
      *c No. 2 Camshaft Flange
      *d Gap
      *e No Gap

      Check that there is no gap between the camshaft timing exhaust gear assembly and No. 2 camshaft flange.

    4. Secure 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 NO. 1 CYLINDER TO TDC/COMPRESSION


    1. B000HT6E01
      Text in Illustration
      *a Timing Notch (Groove)

      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. B000NJOE01
      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.

    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. B000MI7E01
      Text in Illustration
      *a Paint Mark
      *b Timing Mark

      Hold up the chain sub-assembly, align the timing mark and paint mark, and install the No. 2 camshaft to the camshaft housing sub-assembly.

      Tech Tips


      • "A" is not a timing mark.

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

  7. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. B000IKHE01
      Text in Illustration
      *a Paint Mark
      *b Timing Mark

      Align the paint mark of the chain sub-assembly and the timing mark of the camshaft timing gear assembly. Then install the camshaft timing gear assembly.

      Tech Tips

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

  8. INSTALL CAMSHAFT


    1. B000NJOE01
      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.

    2. Clean the camshaft journals.

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

    4. B000JJ3E01
      Text in Illustration
      *a Knock Pin Hole
      *b Knock Pin

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

      Note

      Be careful not to damage the contact surface of the camshaft timing gear assembly with the knock pin of the camshaft.

    5. B000MQHE01
      Text in Illustration
      *1 Camshaft Timing Gear Assembly
      *a Incorrect
      *b Correct
      *c Portion (A) of Camshaft
      *d Gap
      *e No Gap

      Check that there is no gap between the camshaft timing gear assembly and portion (A) of the camshaft shown in the illustration.

      Tech Tips

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

  9. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT

    Note

    There are different types of camshaft timing gear bolts. Make sure to check the identification mark to determine the tightening torque.

    Identification Mark
    Item Identification Mark Stamp
    Type A A
    Type B D
    B000KQYE01
    Text in Illustration
    *a Identification Mark Stamp

    1. B000NJV

      Apply engine oil to the areas of the camshaft timing gear bolt shown in the illustration.

    2. Temporarily install the camshaft timing gear bolt.

      Tech Tips

      Make sure that the camshaft timing gear bolt is screwed in by at least 3 threads.

  10. INSTALL CAMSHAFT BEARING CAP


    1. Place the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap in their correct positions.

    2. B000IJSE02

      Uniformly tighten the 10 bolts in several steps in the order shown in the illustration.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }
    3. B000N1PE02

      Uniformly tighten the 11 bolts in several steps in the order shown in the illustration.

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

    4. Check the torque of each bolt again.

  11. TIGHTEN CAMSHAFT TIMING GEAR BOLT

    B000KQYE01
    Text in Illustration
    *a Identification Mark Stamp

    Note

    There are different types of camshaft timing gear bolts. Make sure to check the identification mark to determine the tightening torque.

    Identification Mark
    Item Identification Mark Stamp
    Type A A
    Type B D

    1. B000M7SE01
      Text in Illustration
      *a Slack

      Check that there is some slack in the chain sub-assembly as shown in the illustration.

    2. B000HZ6E01
      Text in Illustration
      *a Hold
      B000K70 Turn

      Use a wrench to hold the hexagonal portion of the camshaft.

    3. Tighten the camshaft timing gear bolt.

      Torque:
      Type A
      120 N*m  { 1224 kgf*cm, 89 ft.*lbf }
      Type B
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

      Note

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

    4. B000JYTE01
      Text in Illustration
      *a Paint Mark
      *b Timing Mark

      Check that the paint marks of the chain sub-assembly are aligned with the timing mark of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly.

      Tech Tips

      "A" is not a timing mark.

  12. ADD ENGINE OIL


    1. B000JRO

      Add 50 cc (3.1 cu. in.) of engine oil into the oil hole shown in the illustration.

      Note


      • Engine 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.

  13. INSTALL TIMING CHAIN GUIDE


    1. B000N2D

      Install the timing chain guide with the bolt.

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

  14. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B000NE9E01

      Turn the crankshaft pulley approximately 15° clockwise.

    2. 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.

  15. SET 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.

      B000HR9E01
      Text in Illustration
      *a Timing Mark *b Timing Notch (Groove)
      *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.

  16. INSTALL TIMING CHAIN COVER PLATE


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

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

  17. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY


    1. B000IAQE01
      Text in Illustration
      *1 O-ring

      Apply engine oil to a new O-ring and install it to the camshaft timing oil control solenoid assembly as shown in the illustration.

      Note

      Do not damage the O-ring.

    2. B000IN0E21
      Text in Illustration
      *a Adhesive 1324

      Apply adhesive to 2 or 3 threads of 2 new bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

    3. Install the camshaft timing oil control solenoid assembly to the timing chain cover sub-assembly with the 2 bolts.

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

      Note


      • If the camshaft timing oil control solenoid assembly has been struck or dropped, replace it.

      • Make sure that the O-ring is not cracked or moved out of place when installing the camshaft timing oil control solenoid assembly.

    4. Connect the camshaft timing oil control solenoid assembly connector.

  18. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B000JJVE01
      Text in Illustration
      *1 Camshaft Bearing Cap Oil Hole Gasket
      *a Gasket

      Apply a light coat of engine oil to a new camshaft bearing cap oil hole gasket and a new gasket.

    2. Install the camshaft bearing cap oil hole gasket to the No. 1 camshaft bearing cap.

    3. Install the gasket to the No. 2 camshaft bearing cap.

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

      Note

      Remove any oil from the contact surface.

    5. B000NAYE01
      Text in Illustration
      *1 Timing Chain Cover Sub-assembly
      *2 Camshaft Housing Sub-assembly
      *a 45 mm (1.77 in.)
      *b 24 mm (0.945 in.)
      *c Seal Packing Diameter: 3.0 mm (0.118 in.)
      *d Application Width 5.0 mm (0.197 in.)
      *e Seal Packing Diameter: 3.0 to 6.0 mm (0.118 to 0.236 in.)
      B000K70 Seal Packing

      Apply seal packing as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

    6. B000M8NE01

      Align the cylinder head cover sub-assembly with the pin (A). Then align the cylinder head cover sub-assembly with the pin (B) and install the cylinder head cover sub-assembly.

      Text in Illustration
      B000K70 Bolt
      B000IB9 Bolt with Seal Washer

    7. Install 3 new seal washers and the 17 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 start the engine for at least 2 hours after installation.

  19. CONNECT NO. 2 VENTILATION HOSE


    1. Connect the No. 2 ventilation hose to the PCV valve (ventilation valve sub-assembly) and slide the clip to secure it.

  20. INSTALL IGNITION COIL ASSEMBLY

    Tech Tips

    Perform "Inspection After Repair" after replacing an ignition coil assembly Click here.


    1. Install the 4 ignition coil assemblies to the cylinder head cover sub-assembly with the 4 bolts.

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

      Note

      If an ignition coil assembly has been struck or dropped, replace it.

      Tech Tips

      Install the same parts to their original positions.

    2. Connect the 4 ignition coil assembly connectors.

  21. INSTALL ENGINE MOVING CONTROL ROD BRACKET

  22. INSTALL NO. 2 ENGINE MOUNTING STAY RH

  23. INSTALL EARTH WIRE

  24. INSTALL VACUUM PUMP ASSEMBLY

    Click here

  25. INSTALL FUEL PUMP WITH SEAL SUB-ASSEMBLY (for High Pressure)

    Click here

  26. CONNECT ENGINE WIRE


    1. Connect the engine wire to the engine assembly with the 4 nuts and 5 bolts.

      B000HYLE01
      Text in Illustration
      B000K70 Connector B000IB9 Nut
      B000JQI Bolt - -
      Torque:
      Nut (A)
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
      Nut (B) and Bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Connect the 18 connectors and 8 clamps.

    3. Engage the clamp to connect the heater inlet water hose.

  27. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

  28. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  29. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE


    1. Connect the air cleaner cap with air cleaner hose to the throttle body with motor assembly.

    2. Install the air cleaner cap with air cleaner hose with the 2 guides and 2 air cleaner cap clamps.

    3. Tighten the hose clamp.

    4. Connect the union to connector tube hose to the air cleaner hose sub-assembly.

    5. Engage the wire harness clamp.

    6. Connect the mass air flow meter sub-assembly connector.

    7. Engage the ventilation hose clamp.

    8. Connect the ventilation hose to the cylinder head cover sub-assembly and slide the clip to secure it.

  30. INSTALL INLET AIR CLEANER ASSEMBLY

  31. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

  32. INSTALL COOL AIR INTAKE DUCT SEAL

  33. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  34. INSPECT FOR ENGINE OIL LEAK

  35. INSTALL FRONT FENDER APRON SEAL RH

  36. INSTALL ENGINE UNDER COVER RH

  37. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

  38. INSTALL FRONT WHEEL RH

    Torque:
    103 N*m  { 1049 kgf*cm, 76 ft.*lbf }

  39. OPERATION CHECK

    Click here