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CAMSHAFT INSTALLATION

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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 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)

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Supply pump assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing chain case assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Fuel inlet pipe sub-assembly

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

  • The injector assembly is a precision instrument. Do not use the injector assembly if it is struck or dropped.

  • Make sure foreign matter does not enter the fuel path.

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PROCEDURE


  1. Click here

    INSTALL CAMSHAFT


    1. B0024T7C01
      *1 Valve Rocker Arm Sub-assembly
      *2 Valve Stem Cap
      *3 Valve Lash adjuster assembly

      Check that the valve rocker arm sub-assembly is firmly set to the valve lash adjuster assembly.

    2. Apply a light coat of engine oil to the camshaft journals of the cylinder head sub-assembly and the thrust portion of the camshaft.

    3. B0024KBC01
      *a Paint Mark
      *b Timing Mark

      Align the paint mark of the No. 2 chain sub-assembly and timing mark of the camshaft timing sprocket, and install the camshaft timing sprocket to the No. 2 chain sub-assembly.

      Tip:

      Make sure the timing mark of the camshaft timing sprocket face the front side.

    4. B0027DU

      Align the knock pin of the No. 1 camshaft to the groove of the sprocket and install the No. 1 camshaft to the camshaft timing sprocket, and set the bolt.

    5. B002831C01
      *a Paint Mark
      *b Timing Mark

      Align the paint mark of the No. 2 chain sub-assembly and timing mark of the camshaft timing sprocket, and install the camshaft timing sprocket to the No. 2 chain sub-assembly.

      Tip:

      Make sure the timing mark of the camshaft timing sprocket face the front side.

    6. B00269Z

      Align the knock pin of the No. 2 camshaft to the groove of the sprocket and install the No. 2 camshaft to the camshaft timing sprocket, and set the bolt.

      B0028J0C01
      *a Glove
      Tip:

      Glove is at the rear end of the No. 2 camshaft.

    7. B0028GYC01
      *a Paint Mark
      *b Timing Mark

      Check the timing mark of the camshaft timing sprocket and paint mark of the No. 2 chain sub-assembly.

    8. B0024R7

      Set the No. 1 camshaft bearing cap and 8 No. 2 camshaft bearing caps to the cylinder head sub-assembly as shown in the illustration.

    9. Temporarily install the 20 bolts.

    10. B0025BTC01
      B0068HS Bolt A
      B006964 Bolt B

      Uniformly tighten the 20 bolts in several steps in the order shown in the illustration.

      for bolt A
      10 N*m 102 kgf*cm 7 ft.*lbf
      for bolt B
      21 N*m 214 kgf*cm 15 ft.*lbf
    11. B0025FLC01
      *1 No. 1 Camshaft
      *2 No. 2 Camshaft

      Hold the hexagonal portion of the No. 1 camshaft and No. 2 camshaft with a wrench, and tighten the 2 bolts.

      81 N*m 826 kgf*cm 60 ft.*lbf
      Note:

      Be careful not to damage the cylinder head sub-assembly with the wrench.

    12. Remove the pin from the No. 2 chain tensioner assembly.

    13. Install a new gasket and the oil pump relief valve plug to the timing chain cover.

      46 N*m 469 kgf*cm 34 ft.*lbf
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    INSTALL TIMING CHAIN GUIDE


    1. Install the timing chain guide to the cylinder head sub-assembly with the bolt.

      10 N*m 102 kgf*cm 7 ft.*lbf
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    INSTALL CAMSHAFT OIL SEAL RETAINER

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    TEMPORARILY INSTALL VACUUM PUMP ASSEMBLY

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    INSTALL NO. 3 CAMSHAFT BEARING CAP


    1. Clean and degrease the contact surfaces of the cylinder head sub-assembly and No. 3 camshaft bearing cap.

    2. B0026DBC01
      *a Seal Packing

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

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.0 mm (0.118 in.)
      Note:

      • Do not allow seal packing to contact the oil passage of the No. 3 camshaft bearing cap.

      • After applying seal packing, install the No. 3 camshaft bearing cap within 3 minutes and tighten the bolts within 10 minutes.

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

    3. Install the No. 3 camshaft bearing cap with the 2 bolts.

      21 N*m 214 kgf*cm 15 ft.*lbf

    4. Wipe off excess seal packing from between No. 3 camshaft bearing cap and cylinder head sub-assembly.

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    INSTALL VACUUM PUMP ASSEMBLY

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    INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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  8. Click here

    INSTALL NOZZLE HOLDER GASKET

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  9. Click here

    TEMPORARILY INSTALL INJECTOR ASSEMBLY

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    TEMPORARILY INSTALL NO. 1 INJECTION PIPE SUB-ASSEMBLY AND NO. 2 INJECTION PIPE SUB-ASSEMBLY

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    TIGHTEN INJECTOR ASSEMBLY

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    TIGHTEN NO. 1 INJECTION PIPE SUB-ASSEMBLY AND NO. 2 INJECTION PIPE SUB-ASSEMBLY

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    INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY

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    INSTALL HARNESS BRACKET

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    INSTALL WIRING HARNESS CLAMP BRACKET

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    INSTALL NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY

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    INSTALL VACUUM CONTROL VALVE SET

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    INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY (w/o DPF)

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    INSTALL EGR PIPE WITH COOLER SUB-ASSEMBLY (w/ DPF)

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  20. Click here

    CONNECT NO. 4 WATER BY-PASS PIPE SUB-ASSEMBLY

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    INSTALL NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY

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  22. Click here

    INSTALL NO. 2 EGR PIPE

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  23. Click here

    INSTALL EGR VALVE BRACKET

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  24. Click here

    CONNECT ENGINE WIRE

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  25. Click here

    INSTALL NO. 1 UREA TANK FILLER PIPE SUPPORT (w/ Urea SCR System)

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  26. Click here

    CONNECT UREA TANK FILLER PIPE ASSEMBLY (w/ Urea SCR System)

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  27. Click here

    CONNECT FUEL FILTER ASSEMBLY

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  28. Click here

    INSTALL NO. 2 ENGINE COVER BRACKET

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  29. Click here

    INSTALL NO. 2 HOSE TO HOSE TUBE

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  30. Click here

    INSTALL TURBO PRESSURE SENSOR

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  31. Click here

    INSTALL GAS FILTER

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  32. Click here

    INSTALL NO. 1 FUEL PIPE (w/ DPF)

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  33. Click here

    INSTALL NO. 2 WATER BY-PASS PIPE

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  34. Click here

    INSTALL DIESEL THROTTLE BODY ASSEMBLY

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  35. Click here

    INSTALL INTERCOOLER AIR TUBE

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  36. Click here

    INSTALL NO. 4 AIR HOSE

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  37. Click here

    INSTALL RADIATOR ASSEMBLY

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  38. Click here

    CONNECT NO. 2 RADIATOR HOSE

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  39. Click here

    INSTALL FAN SHROUD

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  40. Click here

    CONNECT NO. 1 OIL COOLER INLET HOSE (for Automatic Transmission)

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  41. Click here

    CONNECT NO. 1 OIL COOLER OUTLET HOSE (for Automatic Transmission)

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  42. Click here

    INSTALL RADIATOR RESERVE TANK ASSEMBLY

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  43. Click here

    INSTALL NO. 1 OIL RESERVOIR BRACKET

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  44. Click here

    CONNECT VANE PUMP OIL RESERVOIR ASSEMBLY

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  45. Click here

    INSTALL NO. 1 RADIATOR HOSE

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  46. Click here

    INSTALL NO. 2 AIR TUBE

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  47. Click here

    INSTALL NO. 4 AIR HOSE

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  48. Click here

    INSTALL NO. 1 RADIATOR AIR GUIDE

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  49. Click here

    INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

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  50. Click here

    INSTALL FRONT BUMPER

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  51. Click here

    INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY (for 4WD and Pre-Runner)

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  52. Click here

    CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

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

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  53. Click here

    ADD ENGINE COOLANT

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    INSPECT FOR COOLANT LEAK

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    BLEED AIR FROM FUEL SYSTEM

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    INSPECT FOR FUEL LEAK

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