CAMSHAFT INSTALLATION

PROCEDURE


  1. INSTALL NO. 1 CAMSHAFT BEARING


    1. Clean both surfaces of the No. 1 camshaft bearings.

    2. Install the 2 No. 1 camshaft bearings.

    3. A01KT35C03
      *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)
      0.7 mm (0.0276 in.) or less

      Note

      Position the No. 1 camshaft bearings to the center of the camshaft bearing cap by measuring dimensions A and B.

  2. INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean both surfaces of the No. 2 camshaft bearings.

    2. Install the 2 No. 2 camshaft bearings.

    3. A01KS1CC01
      *a Vernier Caliper

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

      Dimension (A)
      1.05 to 1.75 mm (0.0413 to 0.0689 in.)

      Note

      Position the No. 2 camshaft bearings to the center of the camshaft bearing cap by measuring dimension A.

  3. INSTALL NO. 2 CAMSHAFT


    1. Clean the camshaft journals.

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

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

  4. INSTALL CAMSHAFT


    1. Clean the camshaft journals.

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

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

  5. INSTALL CAMSHAFT BEARING CAP


    1. Apply engine oil to the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.

    2. A01KSVYC05
      *1 Camshaft
      *a Straight Pin

      Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.

    3. A01KS0UN01

      Tighten the 10 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. A01KS05C02
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Stem Cap
      *3 Valve Lash Adjuster Assembly
      *a Correct
      *b Incorrect

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

    2. A01KSDVN03
      *1 7.0 mm
      *2 8.0 mm
      *3 3.5 to 4.5 mm

      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
      Area Specified Condition
      Continuous line 3.5 to 4.5 mm (0.138 to 0.177 in.)
      A 8.0 mm (0.315 in.)
      B 7.0 mm (0.276 in.)
      Application Length A and B
      15 mm (0.591 in.)

      Note


      • Remove any oil from the contact surfaces.

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

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

    3. A01KR0PN02

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

    4. Install the camshaft housing sub-assembly with the 17 bolts and tighten them in the order shown in the illustration.

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

      Note


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

      • If any of the bolts is 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 is 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 cylinder head sub-assembly.

  7. INSTALL CAMSHAFT TIMING SPROCKET


    1. Tighten the bolt with the camshaft timing sprocket secured in place.

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

  8. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01KU0PC18
      *a Straight Pin
      *b Key Groove

      Put the camshaft timing gear assembly and camshaft together with the straight pin and key groove misaligned as shown in the illustration.

      Note

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

    2. A01KSNKC04
      *a Straight Pin
      *b Key Groove

      Turn the camshaft timing gear assembly as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the straight pin fits into the key groove.

      Note

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

    3. A01KSS5C20
      *1 Camshaft Timing Gear Assembly
      *a Clearance
      *b No Clearance
      *c Flange

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

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

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }
    5. A01KREBC02
      *a Lock

      Check that the camshaft timing gear assembly can move in the retard direction (clockwise) and lock it in the most retarded position.

  9. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. Install the No.1 chain vibration damper with the 2 bolts.

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

  10. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01KSZ9C04
      *1 Timing Gear Key

      Temporarily install the crankshaft pulley bolt.

    2. Turn the crankshaft to position the timing gear key to the top.

    3. A01KTF1C02
      *a Timing Mark (Rectangle)
      *b Timing Mark
      *c Mark (Circle)

      Check that the timing marks on the camshaft timing gear assembly and camshaft timing sprocket are aligned as shown in the illustration.

      Tech Tips

      There are 3 marks on the camshaft timing sprocket. Make sure that the timing mark (rectangle) is at the top.

    4. Remove the crankshaft pulley bolt.

  11. INSTALL CHAIN SUB-ASSEMBLY


    1. A01KTR8C04
      *a Mark Plate (Orange)
      *b Timing Mark (Rectangle)
      *c Mark (Circle)
      *d Place the chain on the sprocket
      *e Pass the chain through the damper

      Align the mark plate (orange) with the timing mark as shown in the illustration and install the chain sub-assembly.

      Tech Tips


      • There are 3 marks on the camshaft timing sprocket. Make sure to align the mark plate with the timing mark (rectangle).

      • Be sure to position the mark plate at the front of the engine.

      • The mark plate on the camshaft side is colored orange.

      • Do not pass the chain sub-assembly around the camshaft timing sprocket of the camshaft timing gear assembly. Only place it on the camshaft timing sprocket.

      • Pass the chain through the No. 1 chain vibration damper.

    2. A01KR88

      Place the chain on the crankshaft without passing it around the shaft.

    3. A01KTRAC02
      *a Mark Plate (Orange)
      *b Timing Mark
      *c Tension the chain sub-assembly

      Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly counterclockwise to align the mark plate (orange) and timing mark, and then install the chain sub-assembly.

    4. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly clockwise.

      Tech Tips

      To tension the chain sub-assembly, slowly turn the camshaft timing gear assembly clockwise to prevent the chain sub-assembly from being misaligned.

    5. A01KTTRC06
      *a Mark Plate (Yellow or Pink)
      *b Timing Mark

      Align the mark plate (yellow or pink) and timing mark and install the chain sub-assembly to the crankshaft timing sprocket.

  12. CHECK NO. 1 CYLINDER TDC/COMPRESSION


    1. Check each timing mark at TDC/compression.

      A01KR9WC01
      *a Timing Mark *b Mark Plate (Orange)
      *c Mark Plate (Yellow or Pink) *d Timing Mark (Rectangle)
      *e Mark (Circle) - -

      Tech Tips

      There are 3 marks on the camshaft timing sprocket. Make sure that the timing mark (rectangle) is at the top.

  13. INSTALL NO. 2 CHAIN VIBRATION DAMPER


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

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

  14. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper to the cylinder block.

  15. INSTALL TIMING CHAIN COVER OIL SEAL

    Click here

  16. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here