CAMSHAFT INSTALLATION

PROCEDURE


  1. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. Clamp the camshaft in a vise.

      Note

      Be careful not to damage the camshaft in the vise between aluminum plates.

    2. B003WETC04
      *1 Pin Hole
      *2 Straight Pin

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

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

      Note

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

    4. Apply a small amount of engine oil to the threads and seat section of the flange bolt.

    5. Install the flange bolt while holding the camshaft.

      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

    6. Check the lock of the camshaft timing gear assembly.


      1. Secure the camshaft in place and confirm that the camshaft timing gear assembly is locked.

        Note

        Be careful not to damage the camshaft.

  2. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. Clamp the camshaft in a vise between aluminum plates.

      Note

      Be careful not to damage the camshaft in the vise.

    2. B003WLEC04
      *1 Pin Hole
      *2 Straight Pin

      Put the camshaft timing exhaust gear assembly and camshaft together by aligning the pin hole and straight pin.

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

      Note

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

    4. Apply a small amount of engine oil to the threads and seat section of the flange bolt.

    5. Install the flange bolt while holding the camshaft.

      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

    6. Check the lock of the camshaft timing exhaust gear assembly.


      1. Secure the camshaft in place and confirm that the camshaft timing gear assembly is locked.

        Note

        Be careful not to damage the camshaft.

  3. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY


    1. B003T40C02
      *1 Notch

      Check that the notch is aligned with the "0" timing mark of the timing chain or belt cover sub-assembly.

    2. B003U86C01
      *1 Timing Mark
      *2 Mark Plate (yellow)
      *a Align

      Align the mark plate (yellow) with the timing mark of the camshaft timing gear assembly as shown in the illustration and install the No. 2 chain sub-asembly to the camshaft timing gear assembly.

    3. Clean the camshaft housing sub-assembly LH and No. 3 camshaft journals, and apply engine oil to them.

    4. B003T05C02
      *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-assembly is installed as shown in the illustration.

    5. B003X6DC03
      *a Place chain sub-assembly on camshaft timing gear assembly

      Install the chain sub-assembly to the No. 3 camshaft sub-assembly, and then install the No. 3 camshaft sub-assembly to the camshaft housing sub-assembly LH.

      Tech Tips


      • Place the chain sub-assembly on the camshaft timing gear assembly but do not engage the teeth of the sprocket and the chain sub-assembly.

      • Install the No. 3 camshaft sub-assembly so that the timing mark is facing upward.

  4. INSTALL NO .4 CAMSHAFT SUB-ASSEMBLY


    1. Clean the camshaft housing sub-assembly LH and No. 4 camshaft journals, and apply engine oil to them.

    2. B003SVJC02
      *1 Mark Plate (yellow)
      *2 Timing Mark

      Pass the No. 4 camshaft sub-assembly through the No. 2 chain sub-assembly from the front of the vehicle, align the mark plate (yellow) with the timing mark and install the No. 2 chain sub-assembly to the camshaft timing exhaust gear assembly LH.

    3. B003WR1

      While lifting up the No. 4 camshaft sub-assembly, pass the No. 3 chain tensioner assembly through the No. 2 chain sub-assembly and set it in place.

    4. Install the No. 4 camshaft sub-assembly to the camshaft housing sub-assembly LH, and then install the No. 3 chain tensioner assembly with the bolt.

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

  5. INSTALL CAMSHAFT BEARING CAP (for Bank 2)


    1. Clean the camshaft bearing caps and apply engine oil to them.

    2. B003T05C02
      *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-assembly is installed as shown in the illustration.

    3. B003UB7C02
      *1 Service Bolt and Washers (used to temporarily secure the camshaft housing sub-assembly LH)
      *a Remove the service bolts and washers used to temporarily secure the camshaft housing sub-assembly LH
      *b Part to be installed
      B003WAF Bolt A
      B003U82 Bolt B

      Check the marks and numbers on the camshaft bearing caps, and then remove the service bolts and washers in the order shown in the illustration.

      Immediately after removing the service bolts and washers in the locations for the camshaft bearing caps, install the camshaft bearing caps with the bolts in the order shown in the illustration.

      Torque:
      for bolt A
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
      for bolt B
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

      Note


      • Be sure to follow the numerical order when performing this procedure.

      • Do not drop the service bolts and washers into the cylinder head sub-assembly LH.

    4. Check the torque of each bolt again.

  6. INSTALL CHAIN SUB-ASSEMBLY (for Bank 2)


    1. B003TJ2C01
      *1 Paint Mark

      Align the paint marks on the camshaft timing gear assembly and chain sub-assembly, and install the chain sub-assembly to the camshaft timing gear assembly.

      Tech Tips

      If the paint marks are not aligned, align them by turning the camshaft timing gear assembly slightly.

  7. INSTALL CAMSHAFT


    1. B003WR5C03
      *a 5 to 10°

      Turn the crankshaft clockwise until it is in the position shown in the illustration so that the chain sub-assembly can be installed easily.

      Note

      When turning the crankshaft, engine oil may spray out of the oil holes.

    2. B003WZKC01
      *1 Timing Mark
      *2 Mark Plate (yellow)
      *a Align

      Align the mark plate (yellow) with the timing mark of the camshaft timing gear assembly as shown in the illustration and install the No. 2 chain sub-assembly to the camshaft timing gear assembly.

    3. Clean the camshaft housing sub-assembly RH and camshaft journals and apply engine oil to them.

    4. B003T05C02
      *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-assembly is installed as shown in the illustration.

    5. B003SXGC02
      *a Place chain sub-assembly on camshaft timing gear assembly

      Install the chain sub-assembly to the camshaft, and then install the camshaft to the camshaft housing sub-assembly RH.

      Tech Tips


      • Place the chain sub-assembly on the camshaft timing gear assembly but do not engage the teeth of the sprocket and the chain sub-assembly.

      • Install the camshaft so that the timing mark is facing upward.

  8. INSTALL NO. 2 CAMSHAFT


    1. Clean the camshaft housing sub-assembly RH and No. 2 camshaft journals, and apply engine oil to them.

    2. B003WXYC02
      *1 Mark Plate (yellow)
      *2 Timing Mark

      Pass the No. 2 camshaft through the No. 2 chain sub-assembly from the front of the vehicle, align the mark plate (yellow) with the timing mark and install the No. 2 chain sub-assembly to the camshaft timing exhaust gear assembly RH.

    3. B003TVV

      While lifting up the No. 2 camshaft, pass the No. 2 chain tensioner assembly through the No. 2 chain sub-assembly and set it in place.

    4. Install the No. 2 camshaft to the camshaft housing sub-assembly RH, and then install the No. 2 chain tensioner assembly with the bolt.

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

  9. INSTALL CAMSHAFT BEARING CAP (for Bank 1)


    1. Clean the camshaft bearing caps and apply engine oil to them.

    2. B003T05C02
      *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-assembly is installed as shown in the illustration.

    3. B003WCSC02
      *1 Service Bolt and Washers (used to temporarily secure the camshaft housing sub-assembly RH)
      *a Remove the service bolts and washers to temporarily secure the camshaft housing sub-assembly RH
      *b Part to be installed
      B003WAF Bolt A
      B003U82 Bolt B

      Check the marks and numbers on the camshaft bearing caps, and then remove the service bolts and washers in the order shown in the illustration.

      Immediately after removing the service bolts and washers in the locations for the bearing caps, install the bearing caps with the bolts in the order shown in the illustration.

      Torque:
      for bolt A
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
      for bolt B
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

      Note


      • Be sure to follow the numerical order when performing this procedure.

      • Do not drop the service bolts and washers into the cylinder head sub-assembly.

    4. Check the torque of each bolt again.

  10. INSTALL CHAIN SUB-ASSEMBLY (for Bank 1)


    1. B003VTDC01
      *1 Paint Mark

      Align the paint marks on the camshaft timing gear assembly and chain sub-assembly, and install the chain sub-assembly to the camshaft timing gear assembly.

      Tech Tips

      If the paint marks are not aligned, align them by turning the camshaft timing gear assembly slightly.

  11. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B003W9EC01
      *a 0°
      *b 30°

      Turn the crankshaft counterclockwise 30° past the "0" timing mark, and then turn it clockwise to align the notch with the "0" timing mark.

    2. Turn the crankshaft slightly to eliminate the slack in the chain sub-assembly.

      Tech Tips

      Make sure there is some slack in the chain sub-assembly around the area where the No. 1 chain tensioner assembly is installed.

    3. B003TIBC08
      *1 Stopper Plate
      *2 Pin
      *a Push

      While turning the stopper plate of the No. 1 chain tensioner assembly clockwise, push in the plunger of the No. 1 chain tensioner assembly as shown in the illustration.

    4. While turning the stopper plate of the No. 1 chain tensioner assembly counterclockwise, insert a pin of 1.27 mm (0.0500 in.) diameter into the holes in the stopper plate and No. 1 chain tensioner assembly to secure the stopper plate in place.

    5. Install the No. 1 chain tensioner assembly with the 2 bolts.

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

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

  12. INSPECT VALVE TIMING


    1. Check that each camshaft timing mark is positioned as shown in the illustration.

      B003VPGC01
      *1 Timing Mark - -
      *a Viewpoint - -

      Note


      • Check each timing mark from a viewpoint directly in line with the center of the camshaft and the timing mark on each camshaft timing gear assembly and camshaft timing exhaust gear assembly.

      • If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.

      Tech Tips

      For Intake Camshaft: Be sure to check mark A at the point when marks B, C and D are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.

      B003US2N04

    2. If the valve timing is misaligned, reinstall the chain sub-assembly again.

    3. Turn the crankshaft 2 revolutions, set the No. 1 cylinder to TDC/compression and check the timing marks again.

  13. INSTALL TIMING CHAIN COVER PLATE


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

      Torque:
      9.1 N*m  { 93 kgf*cm, 81 in.*lbf }

  14. INSTALL SPARK PLUG TUBE GASKET

    Click here

  15. POUR ENGINE OIL

    B003VB8

    Tech Tips

    Before installing the cylinder head cover sub-assemblies, pour engine oil into the oil holes shown in the illustration until the oil holes are filled with engine oil.

  16. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain or belt cover sub-assembly or cylinder head cover sub-assembly.

    2. B003V7MC08
      *1 Timing chain cover sub-assembly
      *2 Camshaft housing sub-assembly RH
      *a 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      *b 5.0 to 10.0 mm (0.197 to 0.394 in.)
      B003WAF 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 blots within 15 minutes after applying seal packing.

      • Do not add engine oil for at least 2 hours after installation.

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

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

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

    5. B003VQLC02
      *a Bolt with cylinder head cover seal washer
      B003WAF Apply adhesive to these bolts

      Apply adhesive to the threads of the 11 bolts indicated by the black arrows in the illustration.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      Tighten the bolts within 3 minute after applying adhesive.

    6. Install the cylinder head cover sub-assembly with the 14 bolts and new 2 cylinder head cover seal washers.

      Torque:
      for bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      except bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    7. Attach the clamps and connect the connectors to the cylinder head cover sub-assembly.

  17. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head LH, timing chain or belt cover sub-assembly or cylinder head cover sub-assembly LH.

    2. B003UT1C08
      *1 Timing chain cover sub-assembly
      *2 Camshaft housing sub-assembly LH
      *a 2.0 to 3.0 mm(0.0787 to 0.118 in.)
      *b 5.0 to 10.0 mm(0.197 to 0.394 in.)
      B003WAF 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 LH within 3 minutes and tighten the blots within 15 minutes after applying seal packing.

      • Do not add engine oil for at least 2 hours after installation.

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

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

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

    5. B003UT4C02
      *a Bolt with cylinder head cover seal washer
      B003WAF Apply adhesive to these bolts

      Apply adhesive to the threads of the 10 bolts indicated by the black arrows in the illustration.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      Tighten the bolts within 3 minute after applying adhesive.

    6. Install the cylinder head cover sub-assembly LH with the 12 bolts and a new cylinder head cover seal washer.

      Torque:
      for bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      except bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    7. Attach the clamps and connect the connectors to the cylinder head cover sub-assembly LH.

  18. CONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

  19. INSTALL NO. 2 OIL PIPE

    Click here

  20. INSTALL NO. 1 OIL PIPE


    1. Install the oil control valve filter LH to the oil pipe union. Install 2 new gaskets and temporarily install the No. 1 oil pipe on the cylinder head cover sub-assembly LH side with the oil pipe union.

      Note


      • Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.

      • Do not touch the mesh when installing the oil control valve filter LH.

    2. Install a new gasket and temporarily install the No. 1 oil pipe on the cylinder head LH side with the oil check valve bolt.

    3. B003TN8

      Using a 17 mm ball joint lock nut wrench, tighten the oil pipe union on the cylinder head cover sub-assembly LH side.

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a ball joint lock nut wrench is combined with a torque wrench

      Click here

    4. Tighten the oil check valve bolt on the cylinder head LH side.

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

      Note

      If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.

  21. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  22. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  23. INSTALL SPARK PLUG

    Click here

  24. INSTALL IGNITION COIL ASSEMBLY

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  25. INSTALL INJECTOR DRIVER

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  26. INSTALL NO. 1 ENGINE COVER

    Click here

  27. INSTALL GENERATOR ASSEMBLY

    Click here

  28. INSTALL FUEL PUMP ASSEMBLY

    Click here

  29. INSTALL BATTERY (for LHD)

    Click here

  30. INSTALL BATTERY (for RHD)

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