CAMSHAFT INSTALLATION


  1. INSTALL CAMSHAFT BEARING CAP LH


    1. Apply a light coat of engine oil to the camshaft journals, camshaft housing and camshaft bearing caps.

    2. Install the No. 3 and No. 4 camshafts to the camshaft housing.

    3. A0159BFE01

      Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.

    4. A015C1BE02

      Temporarily install the 10 bolts in the order shown in the illustration.

  2. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A015BULE01
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Valve Stem Cap
      *3 Valve Lash Adjuster

      Check the valve rocker arms as shown in the illustration.

    2. A015BUTE05
      Text in Illustration
      *1 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
      3.5 to 4.0 mm (0.138 to 0.157 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the camshaft housing within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

    3. A01595UE01
      Text in Illustration
      *A for Intake Side
      *B for Exhaust Side
      *1 Knock Pin
      A015DIT Bolt
      A015CC1 Bolt A

      Install the camshaft housing, and then install the 18 bolts in the order shown in the illustration.

      Torque:
      for bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      except bolt A
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      Note


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

      • Make sure that the knock pins of the camshafts are positioned as shown in the illustration before installing the camshaft housing.

    4. A015BV1E05

      Tighten the 10 bolts in the order shown in the illustration.

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

      Note

      Thoroughly wipe clean any seal packing.

  3. INSTALL CAMSHAFT BEARING CAP RH


    1. Apply a light coat of engine oil to the camshaft journals, camshaft housing and camshaft bearing caps.

    2. Install the No. 1 and No. 2 camshafts to the camshaft housing.

    3. A015C4ME02

      Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.

    4. A015BM7E03

      Temporarily install the 10 bolts in the order shown in the illustration.

  4. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A015BULE01
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Valve Stem Cap
      *3 Valve Lash Adjuster

      Check the valve rocker arms as shown in the illustration.

    2. A01581UE06
      Text in Illustration
      *1 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
      3.5 to 4.0 mm (0.138 to 0.157 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the camshaft housing within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

    3. A0156SNE01
      Text in Illustration
      *A for Exhaust Side
      *B for Intake Side
      *1 Knock Pin
      A015DIT Bolt
      A015CC1 Bolt A

      Install the camshaft housing, and then install the 18 bolts in the order shown in the illustration.

      Torque:
      for bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      except bolt A
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      Note


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

      • Make sure that the knock pins of the camshafts are positioned as shown in the illustration before installing the camshaft housing.

    4. A015CH9E06

      Tighten the 10 bolts in the order shown in the illustration.

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

      Note

      Thoroughly wipe clean any seal packing.

  5. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A015779E02
      Text in Illustration
      *1 Plunger
      *2 Pin
      *a Push

      Install the No. 2 chain tensioner with the 2 bolts.

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

    2. While raising up the No. 2 chain tensioner, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to fix the tensioner in place.

  6. INSTALL NO. 1 CHAIN SUB-ASSEMBLY RH


    1. A015BP9E04
      Text in Illustration
      *1 Mark Plate (Orange)
      *2 Timing Mark

      Align the No. 1 chain's mark plates (orange) with the camshaft timing gear's timing mark and attach the chain to the gear as shown in the illustration.

    2. A015AIKE05
      Text in Illustration
      *1 Timing Mark
      *2 Mark Plate (Orange)

      Align the No. 1 chain's mark plate (orange) with the crankshaft timing gear's timing mark and attach the chain to the gear as shown in the illustration.

    3. A015AFYE04
      Text in Illustration
      *1 Timing Mark
      *2 Mark Plate (Yellow)

      Align the No. 2 chain's mark plates (yellow) with the timing marks (1-dot marks) of the camshaft timing gear and camshaft timing exhaust gear, and attach the No. 2 chain to the gears as shown in the illustration.

      Tech Tips

      The crankshaft timing gear and camshaft exhaust gear are installed with the No. 1 and No. 2 chains connected to the gears.

    4. Install the crankshaft timing sprocket RH to the crankshaft.

    5. Align the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear and install the camshaft timing gear.

    6. Using the hexagonal portion of the No. 2 camshaft, align the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear and install the camshaft timing exhaust gear.

    7. Remove the pin from the No. 2 chain tensioner.

  7. INSTALL NO. 1 CHAIN VIBRATION DAMPER RH


    1. Install the No. 1 chain vibration damper RH with the 2 bolts.

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

  8. INSTALL CHAIN TENSIONER SLIPPER RH

    Tech Tips

    If the No. 1 chain tensioner slipper cannot be installed due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain, and then install the chain tensioner slipper RH.

  9. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY RH


    1. A0156H8E03
      Text in Illustration
      *1 Stopper Plate
      *2 Plunger

      Move the stopper plate upward to release the lock and push the plunger deep into the No. 1 chain tensioner.

    2. Move the stopper plate downward to set the lock and insert a hexagon wrench into the hole of the stopper plate.

    3. Install the No. 1 chain tensioner with the 2 bolts.

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

    4. Remove the hexagon wrench from the No. 1 chain tensioner.

  10. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A0156L2E02
      Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push

      Install the No. 3 chain tensioner with the 2 bolts.

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

    2. While pushing down the No. 3 chain tensioner, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to fix the tensioner in place.

  11. INSTALL NO. 1 CHAIN SUB-ASSEMBLY LH


    1. A015CTKE04
      Text in Illustration
      *1 Mark Plate (Orange)
      *2 Timing Mark

      Align the No. 1 chain's mark plates (orange) with the camshaft timing gear's timing mark and attach the chain to the gear as shown in the illustration.

    2. A015BBGE05
      Text in Illustration
      *1 Timing Mark
      *2 Mark Plate (Orange)

      Align the No. 1 chain's mark plate (orange) with the crankshaft timing gear's timing mark and attach the chain to the gear as shown in the illustration.

    3. A0158NIE04
      Text in Illustration
      *1 Timing Mark
      *2 Mark Plate (Yellow)

      Align the No. 2 chain's mark plates (yellow) with the timing marks (1-dot marks) of the camshaft timing gear and camshaft timing exhaust gear, and attach the No. 2 chain to the gears as shown in the illustration.

      Tech Tips

      The crankshaft timing gear and camshaft exhaust gear are installed with the No. 1 and No. 2 chains connected to the gears.

    4. Install the crankshaft timing sprocket LH to the crankshaft.

    5. Align the knock pin of the No. 3 camshaft with the pin hole of the camshaft timing gear and install the camshaft timing gear.

    6. Using the hexagonal portion of the No. 4 camshaft, align the knock pin of the No. 4 camshaft with the pin hole of the camshaft timing exhaust gear and install the camshaft timing exhaust gear.

      Note

      Because the gears' timing mark positions may shift due to looseness of the No. 1 chain, use the hexagonal portion of the camshaft to hold the No. 3 camshaft in place until the No. 1 chain tensioner is installed.

    7. Remove the pin from the No. 3 chain tensioner.

  12. INSTALL CHAIN TENSIONER SLIPPER LH

    Tech Tips

    If the chain tensioner slipper cannot be installed due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain and install the chain tensioner slipper LH.

  13. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY LH


    1. A0156H8E04
      Text in Illustration
      *1 Stopper Plate
      *2 Plunger

      Move the stopper plate upward to release the lock and push the plunger deep into the No. 1 chain tensioner.

    2. Move the stopper plate downward to set the lock and insert a hexagon wrench into the hole of the stopper plate.

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

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

  14. INSTALL NO. 1 CHAIN VIBRATION DAMPER LH


    1. Install the No. 1 chain vibration damper with the 2 bolts.

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

    2. Remove the hexagon wrench from the No. 1 chain tensioner.

  15. TIGHTEN CAMSHAFT TIMING GEAR ASSEMBLY


    1. for Bank 1:


      1. A015AVOE02
        Text in Illustration
        *a Hold
        A015DIT Turn

        Using a wrench to hold the hexagonal portion of the No. 3 camshaft, install the camshaft timing gear bolt.

        Torque:
        100 N*m  { 1020 kgf*cm, 74 ft.*lbf }
      2. A015ADGE02
        Text in Illustration
        *a Hold
        A015DIT Turn

        Using a wrench to hold the hexagonal portion of the No. 4 camshaft, install the camshaft timing exhaust gear bolt.

        Torque:
        100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

    2. for Bank 2:


      1. A0156L9E01
        Text in Illustration
        *a Hold
        A015DIT Turn

        Using a wrench to hold the hexagonal portion of the No. 1 camshaft, install the camshaft timing gear bolt.

        Torque:
        100 N*m  { 1020 kgf*cm, 74 ft.*lbf }
      2. A015DT9E01
        Text in Illustration
        *a Hold
        A015DIT Turn

        Using a wrench to hold the hexagonal portion of the No. 2 camshaft, install the camshaft timing exhaust gear bolt.

        Torque:
        100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

  16. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the pulley set bolt.

    2. Rotate the crankshaft clockwise and check that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration.

    3. Remove the crankshaft pulley set bolt.

      A015CEKE02
      Text in Illustration
      *1 Crankshaft Timing Gear Key *2 Timing Mark
      *a Toward Ceiling *b Timing Mark Position
      *c Knock Pin Position *d Approximately 2°
      *e Approximately 45° *f Approximately 16°
      *g Approximately 18° *h Approximately 32°

  17. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  18. INSPECT IGNITION TIMING

    Note


    • Turn all electrical systems off.

    • Perform the inspection when the cooling fan motor is turned off.


    1. Warm up the engine.

    2. When using the GTS:


      1. Connect the GTS to the DLC3.

      2. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / IGN Advance.

        Standard ignition timing
        7 to 24° BTDC @ idle (transmission in neutral and A/C switch off)

        Tech Tips

        Refer to the GTS operator's manual for further details.

      3. Check that the ignition timing advances immediately when the engine speed is increased.

      4. Disconnect the GTS from the DLC3.

    3. When not using the GTS:


      1. A0159JBE05
        Text in Illustration
        *a Front view of DLC3

        Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.

        SST
        09843-18040

        Note

        Be sure not to improperly connect the terminals. This may damage the engine.

      2. Connect the tester probe of a timing light to the wire of the ignition coil connector for the No. 1 cylinder.

        Note

        Use a timing light that detects primary signals.

      3. Inspect the ignition timing during idling.

        Standard ignition timing
        8 to 12° BTDC @ idle (transmission in neutral and A/C switch off)

      4. Remove SST from the DLC3.

      5. Inspect the ignition timing during idling.

        Standard ignition timing
        7 to 24° BTDC @ idle (transmission in neutral and A/C switch off)

      6. Disconnect the timing light from the engine.

  19. INSPECT ENGINE IDLE SPEED

    Note


    • Turn all the electrical systems off.

    • Perform the inspection when the cooling fan motor is turned off.


    1. Warm up the engine.

    2. When using the GTS:


      1. Connect the GTS to the DLC3.

      2. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Engine Speed.

        Standard idle speed
        650 to 750 rpm (transmission in neutral and A/C switch off)

        Tech Tips

        Refer to the GTS operator's manual for further details.

      3. Disconnect the GTS from the DLC3.

    3. When not using the GTS:


      1. A0159JBE06
        Text in Illustration
        *a Front view of DLC3

        Connect SST to terminal 9 (TAC) of the DLC3.

        SST
        09843-18030

        Note

        Be sure not to improperly connect SST. This may damage the engine.

      2. Race the engine at 2500 rpm for approximately 90 seconds.

      3. Inspect the engine idle speed.

        Standard idle speed
        650 to 750 rpm (transmission in neutral and A/C switch off)