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 camshaft bearing to the camshaft housing.

    3. Using a vernier caliper, measure the distance between the camshaft housing edge and the camshaft bearing edge.

      A011SCOE04
      Standard distance
      1.15 to 1.85 mm (0.0453 to 0.0728 in.)
      Text in Illustration
      *1 Vernier Caliper

  2. INSTALL NO. 1 CAMSHAFT BEARING

    1. Clean the No. 1 camshaft bearing.

      A011RLZE03
      Text in Illustration
      *1 Vernier Caliper

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

    3. Using a vernier caliper, measure the distance between the camshaft bearing cap edge and the 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. Install the oil control valve filter to the No. 1 camshaft bearing cap.

      A011T4Z

  4. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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

      A011RG6E06
      Text in Illustration
      *1 Knock Pin
      *a Knock Pin Hole

    2. Check that there is no clearance between the camshaft timing exhaust gear assembly and camshaft flange.

      A011SR5E10
      Text in Illustration
      *1 Camshaft Timing Exhaust Gear Assembly
      *2 Clearance
      *3 Camshaft Flange
      *a INCORRECT
      *b CORRECT
      *c No Clearance

    3. Fix the camshaft timing exhaust gear assembly with the bolt.

      A011V8G
      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 TDC/COMPRESSION

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

      A011UXHE02
      Text in Illustration
      *a Timing Notch

  6. INSTALL NO. 2 CAMSHAFT

    1. Make sure that the valve rocker arms are installed as shown in the illustration.

      A011UNKE06
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Valve Lash Adjuster
      *3 Valve Stem Cap

    2. Clean the camshaft journals.

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

    4. Hold up the chain and align the timing mark and the paint mark, and install the camshaft.

      A011TZHE02
      Text in Illustration
      *a Paint Mark
      *b Timing Mark

      Tech Tips

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

  7. INSTALL CAMSHAFT

    1. Make sure that the valve rocker arms are installed as shown in the illustration.

      A011UNKE06
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Valve Lash Adjuster
      *3 Valve Stem Cap

    2. Clean the camshaft journals.

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

    4. Install the camshaft to the camshaft housing as shown in the illustration.

      A011RXSE01
      Text in Illustration
      *1 Knock Pin
      *a Approximately 17°

      Tech Tips

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

  8. INSTALL CAMSHAFT BEARING CAP

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

      A011UCH

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

      A011SI7E02
      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

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

      A011THVE02
      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. Check the camshaft timing gear position.

      A011QR6E05
      Text in Illustration
      *a Advanced Position
      *b Retarded Position
      *c Knock Pin Hole
      *d Alignment Mark

      Note

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

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

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

      A011QQDE01
      Text in Illustration
      *a Narrow
      *b Wide

    3. Turn the camshaft timing gear assembly approximately 180° counterclockwise.

      A011T6EE01
      Text in Illustration
      *a Narrow
      *b Wide

    4. Align the paint mark with the timing mark to install the chain.

      A011SZWE02
      Text in Illustration
      *a Paint Mark
      *b Timing Mark

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

      A011T73E05
      Text in Illustration
      *1 Knock Pin
      *a Knock Pin Hole

    6. Check that there is no clearance between the camshaft timing gear and camshaft flange.

      A011SR5E10
      Text in Illustration
      *1 Camshaft Timing Gear
      *2 Clearance
      *3 Camshaft Flange
      *a INCORRECT
      *b CORRECT
      *c No Clearance

    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. 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.

        A011V3JE02
        Text in Illustration
        *a Make a Hole
        *b Adhesive Tape Sealing Area

        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. 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.

        A011R21

        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 in the advance direction (counterclockwise).

        Tech Tips

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

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

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

      A011UDQ
      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Note

      Be careful not to damage the cylinder head or spark plug tube with the wrench.

    10. Check that each matchmark of the camshaft timing gear and camshaft timing exhaust gear are aligned with each matchmark located as shown in the illustration.

      A011S4ME02
      Text in Illustration
      *a Paint Mark
      *b Timing Mark

      Tech Tips

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

  10. ADD ENGINE OIL

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

      A011U4G

      Note

      • Oil must be added if the lash adjusters were removed.

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

  11. INSTALL TIMING CHAIN GUIDE

    1. Install the timing chain guide with the bolt.

      A011U2T
      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  12. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    1. Turn the crankshaft approximately 10° clockwise.

      A011UKHE01

    2. Install a new gasket and the chain tensioner with the 2 bolts.

      A011QRO
      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note

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

    3. Remove the pin from the stopper plate.

  13. CHECK 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 are aligned.

      A011QNRE02
      Text in Illustration
      *1 Timing Mark
      *2 Timing Notch
      *a Approximately 7°
      *b Approximately 32°

    2. Check that the timing marks of the camshaft timing gears are 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.

      A011RJ4
      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  15. INSTALL TIMING CHAIN COVER TIGHT PLUG

    1. Using a 14 mm hexagon wrench, install a new gasket and the plug.

      A011UP4
      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  16. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    1. Apply a light coat of engine oil to 3 new gaskets.

      A011RTN

    2. Install the 3 gaskets to the camshaft bearing caps.

    3. Install a new gasket to the cylinder head cover.

      Note

      Remove any oil from the contact surface.

    4. Apply seal packing as shown in the illustration.

      A011SCAE03
      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.)
      Text in Illustration
      *1 Seal packing
      *2 Timing Chain Cover
      *3 Camshaft Housing

      Note

      • Remove any oil from the contact surface.

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

    5. Align the cylinder head cover with pin A. Then align the cylinder head cover with pin B and install the cylinder head cover.

      A011T3IE01

    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 the 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 bolts and nuts.

      A011UY9E01
      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 connectors and clamps.

  19. INSTALL ENGINE MOVING CONTROL ROD

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

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

        A011V6Y

      2. Fully tighten the engine moving control rod bracket with the bolts except bolt A.

        A011UREE01
        Torque:
        38 N*m  { 387 kgf*cm, 28 ft.*lbf }

      3. Fully tighten the bolt A.

        A011U77E01
        SST
        09961-00950
        Torque:
        without SST
        52 N*m  { 530 kgf*cm, 38 ft.*lbf }
        with SST
        33 N*m  { 340 kgf*cm, 25 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 (10.24 in.) Click here.

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

        • Fully tighten the bolt A using SST.

    2. When the engine moving control rod has been reused.

      A011V6YE01

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

      2. Fully tighten the engine moving control rod bracket with the 4 bolts.

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

  20. 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 }

  21. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

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

      A011S9ZE01
      Text in Illustration
      *a Hole
      *b Projection

    2. Tighten the 2 bolts.

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

    3. Connect the wire harness clamp.

  22. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

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

      Note

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

  23. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

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

    2. Install the air cleaner hose with the hose clamp.

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

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

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

    6. Connect the vacuum switching valve assembly to the air cleaner hose.

  24. INSTALL INLET AIR CLEANER ASSEMBLY

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

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

  25. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    1. Connect 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.

  26. INSPECT FOR OIL LEAK

  27. INSTALL FRONT FENDER APRON SEAL RH

  28. INSTALL ENGINE UNDER COVER RH

  29. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

  30. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

    1. Fit the 3 retainers and install the No. 1 engine cover sub-assembly.

  31. INSTALL COOL AIR INTAKE DUCT SEAL

    1. Install the cool air intake duct seal with the 7 clips.

  32. INSTALL FRONT WHEEL RH