CAMSHAFT INSTALLATION

CAUTION / NOTICE / HINT

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly, No. 3 injection pipe sub-assembly, No. 4 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

    Replaced Parts (A) Pipes Requiring New Replacement

    • Injector assembly (including shuffling the injector assemblies between the cylinders)

    • Common rail assembly

    • Cylinder head sub-assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • No. 3 injection pipe sub-assembly

    • No. 4 injection pipe sub-assembly

    • Supply pump assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing Gear Case Assembly

    		 Fuel inlet pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly, No. 3 injection pipe sub-assembly, No. 4 injection pipe sub-assembly and fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

PROCEDURE


  1. INSTALL CAMSHAFT SUB-ASSEMBLY


    1. B003N0VC01
      *1 Key

      Using the crankshaft pulley bolt, set the No. 1 cylinder to 90° BTDC/compression.

      Tech Tips

      Set the No. 1 cylinder to 90° BTDC/compression to prevent the top of the piston from hitting against the valve head.

    2. B003JMJC01
      *a Key Groove
      *b Upward

      Install the camshaft sub-assembly.


      1. Apply engine oil to the thrust portion of the intake camshaft sub-assembly.

      2. Place the intake camshaft sub-assembly on the cylinder head sub-assembly with the key groove facing upward.

      3. B003O1V

        Align the timing marks (1-dot marks) of the camshaft sub-assembly drive and driven main gears and set the exhaust camshaft sub-assembly in place.

    3. Remove any old seal packing (FIPG material) from the No. 1 camshaft bearing cap.

    4. B003LW7C01
      *a Seal Packing
      *b 8.0 mm (0.315 in.)
      *c Oil Passage

      Apply seal packing to the specified areas shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      4 mm (0.157 in.)

      Note


      • Do not allow seal packing to contact the oil passage of the camshaft bearing cap.

      • After applying seal packing, install the camshaft bearing caps within 3 minutes and tighten the bolts within 15 minutes.

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

    5. B003OAP

      Install the No. 1 camshaft bearing cap, 3 No. 2 camshaft bearing caps and No. 3 camshaft bearing cap to their proper locations from the cylinder head sub-assembly.

    6. B003R7SN02

      Apply a light coat of engine oil to the threads and under the heads of the camshaft bearing cap bolts.

    7. Install and uniformly tighten the 15 camshaft bearing cap bolts in several passes in the sequence shown in the illustration.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }
    8. B003J9GN01

      Install a new camshaft oil seal.


      1. Apply MP grease to the lip of a new camshaft oil seal.

      2. Using SST and a hammer, tap in the camshaft oil seal until its surface is flush with the surfaces of the camshaft bearing cap and cylinder head sub-assembly.

        SST
        09608-06041

  2. INSTALL NO. 2 TIMING BELT COVER

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  3. INSTALL CAMSHAFT TIMING PULLEY

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  4. INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY

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  5. INSTALL TIMING BELT

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  6. INSPECT AND ADJUST VALVE CLEARANCE

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  7. INSTALL NO. 1 TIMING BELT COVER

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  8. INSTALL INJECTOR ASSEMBLY

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  9. INSPECT FOR FUEL LEAK

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  10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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  11. INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

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  12. INSTALL NO. 4 INJECTION PIPE SUB-ASSEMBLY

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  13. INSTALL NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY

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  14. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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  15. INSTALL MANIFOLD STAY

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  16. INSTALL NO. 1 INTAKE PIPE

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  17. INSTALL FAN SHROUD

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  18. INSTALL NO. 1 RADIATOR HOSE

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  19. ADD ENGINE OIL

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  20. BLEED AIR FROM FUEL SYSTEM

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  21. ADD ENGINE COOLANT

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  22. INSPECT FOR COOLANT LEAK

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  23. INSPECT FOR OIL LEAK

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  24. INSPECT FOR FUEL LEAK

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  25. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

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  26. INSPECT ENGINE OIL LEVEL

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