CAMSHAFT(w/o EGR Cooler) 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 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 Fuel inlet pipe sub-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.

PROCEDURE


  1. 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.

      Tech Tips

      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.

      Tech Tips

      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.

      Tech Tips

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

      B0028J0C01
      *a Groove
    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.

      Torque:
      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.

      Torque:
      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.

      Torque:
      46 N*m  { 469 kgf*cm, 34 ft.*lbf }

  2. INSTALL TIMING CHAIN GUIDE


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

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

  3. INSTALL CAMSHAFT OIL SEAL RETAINER

    Click here

  4. TEMPORARILY INSTALL VACUUM PUMP ASSEMBLY

    Click here

  5. 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.

      Torque:
      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.

  6. INSTALL VACUUM PUMP ASSEMBLY

    Click here

  7. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  8. INSTALL NOZZLE HOLDER GASKET

    Click here

  9. TEMPORARILY INSTALL INJECTOR ASSEMBLY

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

    Click here

  11. TIGHTEN INJECTOR ASSEMBLY

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

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  13. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY

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  14. INSTALL HARNESS BRACKET

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  15. INSTALL WIRING HARNESS CLAMP BRACKET

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  16. INSTALL EGR VALVE ADAPTER

    Click here

  17. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  18. INSTALL NO. 2 EGR PIPE

    Click here

  19. INSTALL EGR VALVE BRACKET

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  20. CONNECT ENGINE WIRE

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  21. CONNECT FUEL FILTER ASSEMBLY

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  22. INSTALL NO. 2 ENGINE COVER BRACKET

    Click here

  23. INSTALL NO. 2 HOSE TO HOSE TUBE

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  24. INSTALL TURBO PRESSURE SENSOR

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  25. INSTALL GAS FILTER

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  26. INSTALL NO. 2 WATER BY-PASS PIPE

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  27. INSTALL DIESEL THROTTLE BODY ASSEMBLY

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  28. INSTALL INTERCOOLER AIR TUBE

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  29. INSTALL RADIATOR ASSEMBLY

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  30. CONNECT NO. 2 RADIATOR HOSE

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  31. INSTALL FAN SHROUD

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

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

    Click here

  34. INSTALL RADIATOR RESERVE TANK ASSEMBLY

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  35. INSTALL NO. 1 OIL RESERVOIR BRACKET

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  36. CONNECT VANE PUMP OIL RESERVOIR ASSEMBLY

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  37. INSTALL NO. 1 RADIATOR HOSE

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  38. INSTALL NO. 2 AIR TUBE

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  39. INSTALL NO. 4 AIR HOSE

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  40. INSTALL NO. 1 RADIATOR AIR GUIDE

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  41. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

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  42. INSTALL FRONT BUMPER

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  43. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY (for 4WD)

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  44. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  45. ADD ENGINE COOLANT

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  46. INSPECT FOR COOLANT LEAK

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  47. BLEED AIR FROM FUEL SYSTEM

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  48. INSPECT FOR FUEL LEAK

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