CAMSHAFT INSTALLATION

Tech Tips

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


  1. INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean the No. 2 camshaft bearing.

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

    3. A01G6F4E05
      Text in Illustration
      *1 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
      1.15 to 1.85 mm (0.0453 to 0.0728 in.)

  2. INSTALL NO. 1 CAMSHAFT BEARING


    1. A01G5ZWE02
      Text in Illustration
      *1 Vernier Caliper

      Clean the No. 1 camshaft bearing.

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

    3. 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.)

  3. INSTALL OIL CONTROL VALVE FILTER


    1. A01G5I2

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

  4. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. Secure the No. 2 camshaft in a vise by clamping the hexagonal part using aluminum plates.

      Note

      Do not damage the No. 2 camshaft by tightening the vise excessively.

    2. A01G8E6E03
      Text in Illustration
      *1 Knock Pin
      *a Knock Pin Hole

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

    3. A01G959E11
      Text in Illustration
      *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.

    4. A01G87S

      Secure the camshaft timing exhaust gear assembly with the bolt.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Note

      Do not disassemble the camshaft timing exhaust gear assembly.

      Tech Tips

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

  5. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01G72ZE01
      Text in Illustration
      *a Timing Notch

      Turn the crankshaft pulley until its timing notch (groove) and the timing mark "0" of the timing chain cover sub-assembly are aligned.

  6. INSTALL NO. 2 CAMSHAFT


    1. A01G546E06
      Text in Illustration
      *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.

    2. Clean the camshaft journals.

    3. Apply a light coat of engine oil to the camshaft journals, camshaft housing sub-assembly and bearing caps.

    4. A01G68VE01
      Text in Illustration
      *a Paint Mark
      *b Timing Mark

      Hold up the chain sub-assembly and align the timing mark and the paint mark, and install the No. 2 camshaft.

      Tech Tips


      • "A" is not a timing mark.

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

  7. INSTALL CAMSHAFT


    1. A01G546E06
      Text in Illustration
      *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.

    2. Clean the camshaft journals.

    3. Apply a light coat of engine oil to the camshaft journals, camshaft housing sub-assembly and bearing caps.

    4. A01G7EOE01
      Text in Illustration
      *1 Knock Pin
      *a Approximately 17°

      Install the camshaft to the camshaft housing sub-assembly as shown in the illustration.

      Tech Tips

      Perform "Inspection After Repair" after replacing the camshaft Click here.

  8. INSTALL CAMSHAFT BEARING CAP


    1. A01G823

      Confirm the marks and numbers on the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and 3 No. 3 camshaft bearing caps and place them in their proper positions and directions.

    2. A01G8JQE02

      Using several steps, uniformly tighten the 10 bolts in the sequence shown in the illustration.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }
    3. A01G8OIE02

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

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

    4. Check the torque of each bolt again.

  9. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01G9ENE05
      Text in Illustration
      *a Advance Position
      *b Retard Position
      *c Knock Pin Hole
      *d Alignment Mark

      Check the camshaft timing gear assembly position.

      Note


      • If the camshaft timing gear assembly is set to the advanced position, do not let the camshaft timing gear assembly rotate clockwise during installation.

      • If the camshaft timing gear assembly has rotated to the most retarded position, make sure to release the lock pin and set the camshaft timing gear assembly to the most advanced position before tightening the camshaft timing gear assembly.

    2. A01G6K4E01
      Text in Illustration
      *a Narrow
      *b Wide

      Install the camshaft timing gear assembly as shown in the illustration.

    3. A01G8Y3E01
      Text in Illustration
      *a Narrow
      *b Wide

      Turn the camshaft timing gear assembly approximately 180° counterclockwise.

    4. A01G9VJE03
      Text in Illustration
      *a Paint Mark
      *b Timing Mark

      Align the paint mark with the timing mark and install the chain sub-assembly to the camshaft timing gear assembly.

      Tech Tips

      "A" is not a timing mark.

    5. A01G9DKE04
      Text in Illustration
      *1 Knock Pin
      *a Knock Pin Hole

      Align and insert the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly.

    6. A01G959E11
      Text in Illustration
      *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.

    7. Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear assembly by hand.

      Note

      Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

    8. If the lock pin has not been released, release it.


      1. A01G6AAE02
        Text in Illustration
        *a Make a Hole
        *b Adhesive Tape Sealing Area

        After cleaning and degreasing the intake side VVT oil hole on the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.

        Note

        Be sure to seal the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

      2. Make a hole in the adhesive tape covering the oil hole as shown in the illustration. (Procedure A)

      3. A01G4EM

        Apply approximately 200 kPa (2.0 kgf/ cm2, 29 psi) of air pressure to the hole made in procedure A to release the lock pin.

        Note


        • If air leaks out, reattach the adhesive tape.

        • Cover the oil hole with a piece of cloth when applying air pressure to prevent oil from spraying.

      4. Forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

        Tech Tips


        • Depending on the air pressure applied, the camshaft timing gear assembly may turn in the advance direction without assistance by hand.

        • If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.

      5. Remove the adhesive tape from the No. 1 camshaft bearing cap.

    9. A01G5P1

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

      Torque:
      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.

    10. A01G9GGE01
      Text in Illustration
      *a Paint Mark
      *b Timing Mark

      Check that both timing marks on the camshaft timing gear assembly and camshaft timing exhaust gear assembly are facing upward as shown in the illustration.

      Tech Tips


      • "A" is not a timing mark.

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

  10. ADD ENGINE OIL


    1. A01G9UK

      Add 50 cc (3.1 cu. in.) of engine oil into the oil hole shown in the illustration.

      Note


      • Oil must be added if the valve lash adjuster assemblies were removed.

      • Make sure that the low pressure chamber and oil paths of the valve lash adjuster assemblies are full of engine oil.

  11. INSTALL TIMING CHAIN GUIDE


    1. Install the timing chain guide with the bolt.

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

  12. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01G9ESE01

      Turn the crankshaft pulley approximately 10° clockwise.

    2. Install a new gasket and the No. 1 chain tensioner assembly with the 2 bolts.

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

      Note

      Make sure not to drop the gasket inside the timing chain cover sub-assembly.

    3. Remove the pin from the stopper plate.

  13. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Turn the crankshaft pulley until its timing notch (groove) and the timing mark "0" of the timing chain cover sub-assembly are aligned.

      A01G92LE01
      Text in Illustration
      *a Timing Mark *b Timing Notch
      *c Approximately 7° *d Approximately 32°

    2. Check that both timing marks on the camshaft timing gear assembly and camshaft timing exhaust gear assembly are facing upward as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration.

      Tech Tips

      "A" is not a timing mark.

  14. INSTALL TIMING CHAIN COVER PLATE


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

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

  15. INSTALL TIMING CHAIN COVER TIGHT PLUG


    1. A01G6VF

      Using a 14 mm hexagon wrench, install a new gasket and the timing chain cover tight plug.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  16. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01G8SQ

      Apply a light coat of engine oil to 3 new camshaft bearing cap oil hole gaskets.

    2. Install the 3 camshaft bearing cap oil hole gaskets.

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

      Note

      Remove any oil from the contact surface.

    4. A01G7Q8E03
      Text in Illustration
      *1 Seal Packing
      *2 Timing Chain Cover Sub-assembly
      *3 Camshaft Housing Sub-assembly

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.0 to 6.0 mm (0.118 to 0.236 in.)
      Application width A
      5.0 mm (0.197 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

    5. A01G8SME01

      Align the cylinder head cover sub-assembly with the pin A. Then align the cylinder head cover sub-assembly with the pin B and install the cylinder head cover sub-assembly.

    6. Install 3 new seal washers and the 16 bolts, and then tighten the bolts in the order shown in the illustration.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

      Note

      Do not apply oil for at least 2 hours after the installation.

  17. INSTALL IGNITION COIL ASSEMBLY


    1. Install the 4 ignition coil assemblies with the 4 bolts.

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

      Tech Tips

      Perform "Inspection After Repair" after replacing an ignition coil assembly Click here.

    2. Connect the 4 ignition coil assembly connectors.

  18. CONNECT ENGINE WIRE


    1. Install the engine wire to the engine with the 3 bolts and 4 nuts.

      A01G7QPE01
      Torque:
      Nut A
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
      Nut B
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Connect the 12 connectors and 5 clamps.

    3. Engage the 2 claws to connect the inlet heater water hose and outlet heater water hose A.

  19. INSTALL NO. 2 ENGINE ROOM RELAY BLOCK (for LHD)


    1. Install the No. 2 engine room relay block with the bolt and 2 clamps.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Install the front fender liner RH with the screw.

  20. INSTALL ENGINE MOVING CONTROL ROD BRACKET


    1. When the engine moving control rod has been replaced.


      1. A01G6CT

        Temporarily install the engine moving control rod bracket with the 4 bolts.

      2. Fully tighten the 4 bolts.

        Torque:
        38 N*m  { 387 kgf*cm, 28 ft.*lbf }
      3. A01G73IE01

        Using SST, fully tighten the bolt.

        SST
        09961-00950
        Torque:
        without SST
        52 N*m  { 530 kgf*cm, 38 ft.*lbf }
        with SST
        33 N*m  { 337 kgf*cm, 24 ft.*lbf }

        Note


        • The "with SST" torque value is effective when using SST with a fulcrum length of 150 mm (5.91 in.) and a torque wrench with a fulcrum length of 260 mm (10.2 in.) Click here.

        • The "with SST" torque value is effective when SST is parallel to the torque wrench.

    2. A01G6CTE01

      When the engine moving control rod has been reused.


      1. Temporarily install the engine moving control rod bracket with the 4 bolts.

      2. Fully tighten the 4 bolts.

        Torque:
        38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  21. INSTALL EARTH WIRE


    1. Install the earth wire to the engine moving control rod bracket with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  22. INSTALL NO. 2 ENGINE MOUNTING STAY RH


    1. Install the No. 2 engine mounting stay RH with the 2 bolts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  23. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. A01G579E01
      Text in Illustration
      *a Hole
      *b Projection

      Insert the projection of the air cleaner case sub-assembly into the hole of the No. 2 air cleaner bracket as shown in the illustration.

    2. Install the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    3. Connect the wire harness clamp.

  24. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. Install the air cleaner filter element sub-assembly to the air cleaner case sub-assembly.

      Note

      Install the air cleaner filter element sub-assembly with the printed side facing the vehicle front.

  25. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. A01G6AKE01
      Text in Illustration
      *a Hinge
      *b Clamp

      Connect the 2 hinges of the air cleaner cap sub-assembly.

    2. Install the air cleaner cap sub-assembly with the 2 clamps.

    3. Connect the air cleaner cap sub-assembly to the throttle with motor body assembly the hose clamp.

    4. Connect the ventilation hose to the cylinder head cover.

    5. Install the fuel vapor feed hose to the air cleaner hose.

    6. Connect the mass air flow meter connector and 2 wire harness clamps to the air cleaner cap sub-assembly.

    7. Connect the vacuum switching valve assembly to the air cleaner cap sub-assembly.

  26. INSTALL INLET AIR CLEANER ASSEMBLY


    1. Install the inlet air cleaner assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  27. INSTALL COOL AIR INTAKE DUCT SEAL


    1. Install the cool air intake duct seal with the 9 clips.

  28. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


    1. Connect the cable to the negative (-) battery terminal.

      Torque:
      6.9 N*m  { 70 kgf*cm, 61 in.*lbf }

      Note

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

  29. INSPECT FOR OIL LEAK

  30. INSTALL FRONT FENDER APRON SEAL RH

  31. INSTALL ENGINE UNDER COVER RH

  32. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

  33. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. Engage the 3 pins to install the No.1 engine cover sub-assembly.

  34. INSTALL FRONT WHEEL RH

    Torque:
    103 N*m  { 1049 kgf*cm, 76 ft.*lbf }