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CAMSHAFT INSTALLATION

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CAUTION / NOTICE / HINT

Tip:

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

Click here(w/ EGR System)

Click here(w/o EGR System)

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PROCEDURE


  1. Click here

    INSTALL VALVE LASH ADJUSTER ASSEMBLY

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  2. Click here

    INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

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  3. Click here

    INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean the No. 2 camshaft bearing.

      Note:

      Do not apply engine oil to the No. 2 camshaft bearing or contact surfaces.

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

    3. A01MS5RC03
      *1 Camshft Housing Sub-assembly
      *2 No. 2 Camshaft Bearing
      *3 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
      A=1.15 to 1.85 mm (0.0453 to 0.0728 in.)
  4. Click here

    INSTALL NO. 2 CAMSHAFT

    Tip:

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

    Click here(w/ EGR System)

    Click here(w/o EGR System)


    1. Clean the No. 2 camshaft journals and camshaft housing sub-assembly.

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

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

  5. Click here

    INSTALL CAMSHAFT

    Tip:

    Perform "Inspection After Repair" after replacing the camshaft.

    Click here(w/ EGR System)

    Click here(w/o EGR System)


    1. Clean the camshaft journals and camshaft housing sub-assembly.

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

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

  6. Click here

    INSTALL NO. 1 CAMSHAFT BEARING


    1. Clean the No. 1 camshaft bearing.

      Note:

      Do not apply engine oil to the No. 1 camshaft bearing or contact surfaces.

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

    3. A01MTYYC03
      *1 No. 1 Camshaft Bearing Cap
      *2 No. 1 Camshaft Bearing
      *3 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 or B - A = 0 to 0.7 mm (0 to 0.0276 in.)
  7. Click here

    INSTALL OIL CONTROL VALVE FILTER


    1. Check that there is no foreign matter on the mesh section.

    2. A011NUB

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

      Note:

      Do not touch the mesh section on the oil control valve filter.

  8. Click here

    INSTALL CAMSHAFT BEARING CAP


    1. Clean the camshaft bearing caps.

    2. Apply a light coat of engine oil to the camshaft journals and camshaft bearing caps.

    3. Place the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap.

    4. A01MS8YC04
      *1 No. 1 camshaft bearing cap
      *2 No. 2 camshaft bearing cap
      *3 No. 3 camshaft bearing cap
      *4 No. 4 camshaft bearing cap

      Using several steps, uniformly tighten the 11 bolts in the sequence shown in the illustration.

      16 N*m 163 kgf*cm 12 ft.*lbf
      Note:

      After installing the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap, make sure that the camshaft and No. 2 camshaft rotate smoothly.

  9. Click here

    INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A01MS64C02
      *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
      Standard seal diameter
      3.0 to 4.0 mm (0.118 to 0.157 in.)
      Note:

      • Remove any oil from the contact surface.

      • Check the bolts and bolt holes and clean them.

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

      • Do not add engine oil within 2 hours of installation.

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

    2. A01MSH4C10
      *1 Knock Pin
      *a Approximately 17°
      *b Approximately 2°

      Position the knock pin of the camshaft and No. 2 camshaft as shown in the illustration.

    3. A01MST9C29
      *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.

    4. A01MU12C01
      B003XUN Bolt A
      B003YHT Bolt B

      Install the camshaft housing sub-assembly, and then tighten the 20 bolts in the order shown in the illustration.

      27 N*m 275 kgf*cm 20 ft.*lbf
      Note:

      If the bolts have been loosened during the installation, apply seal packing black to the camshaft housing sub-assembly again.

      Table 1. Standard Bolt
      Item Length
      Bolt A 70 mm (2.76 in.)
      Bolt B 45 mm (1.77 in.)
  10. Click here

    INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

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  11. Click here

    INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    Tip:

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

    Click here(w/ EGR System)

    Click here(w/o EGR System)


    1. When using a new camshaft timing gear assembly:


      1. A01MRQWC14
        *1 Pin Hole
        *a Lock Pin Lock Released
        *b Lock Pin Locked
        *c Lock Check Point

        Check that the camshaft timing gear assembly is not locked.

        Note:

        If locked, release the lock pin of the camshaft timing gear assembly.

        Click here

    2. A01MTWFC02
      *1 Pin Hole
      *2 Knock Pin

      When reusing the camshaft timing gear assembly:


      1. Release the lock pin.

        Click here

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

    4. 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 advanced direction.


      • Do not forcefully press the camshaft timing gear assembly. Otherwise, the tip of knock pin of the camshaft may damage the seal surface of the camshaft timing gear assembly, leading to poor sealing.

    5. A01MSRSC52
      *1 Camshaft Timing Gear Assembly
      *2 Camshaft Flange
      *a Incorrect
      *b Correct
      *c Clearance
      *d No Clearance

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

    6. A01MS8LC02
      *a Hold
      *b Turn

      Using a wrench to hold the hexagonal portion of the camshaft, tighten the bolt.

      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.

      • If the camshaft timing gear assembly has been locked at the most retarded position, release the lock pin first, and then tighten the bolt.

      • The lock pin may be damaged if the bolt is tightened when the camshaft timing gear assembly is locked.

  12. Click here

    INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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  13. Click here

    INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Tip:

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

    Click here(w/ EGR System)

    Click here(w/o EGR System)


    1. A01MSHCC33
      *1 Pin Hole
      *2 Knock Pin

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

      Note:

      Do not forcefully press the camshaft timing exhaust gear assembly. Otherwise, the tip of knock pin of the No. 2 camshaft may damage the seal surface of the camshaft timing exhaust gear assembly, leading to poor sealing.

    2. A01MSRSC52
      *1 Camshaft Timing Exhaust Gear Assembly
      *2 Camshaft Flange
      *a Incorrect
      *b Correct
      *c Clearance
      *d No Clearance

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

    3. A01MRQAC01
      *a Hold
      *b Turn

      Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the bolt.

      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.

  14. Click here

    POUR ENGINE OIL

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  15. Click here

    INSTALL NO. 1 CHAIN VIBRATION DAMPER

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  16. Click here

    INSTALL CHAIN SUB-ASSEMBLY

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  17. Click here

    INSTALL CHAIN TENSIONER SLIPPER

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  18. Click here

    INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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  19. Click here

    INSTALL TIMING CHAIN GUIDE

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  20. Click here

    CHECK NO. 1 CYLINDER TO TDC / COMPRESSION

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  21. Click here

    INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

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