CAMSHAFT INSTALLATION


  1. INSTALL CAMSHAFT TIMING SPROCKET ASSEMBLY

    A0118PTE01
    Text in Illustration
    *1 Straight Pin
    *2 Key Groove

    1. Put the camshaft timing gear assembly and camshaft together with the straight pin and key groove misaligned, as shown in the illustration.

      Note

      Do not forcefully push in the camshaft timing gear assembly. This may cause the camshaft knock pin tip to damage the installation surface of the camshaft timing gear assembly.

  2. INSTALL CAMSHAFT

    A0118NQE01
    Text in Illustration
    *1 Apply Engine Oil

    1. Apply engine oil to the cam of each camshaft, the journals of the cylinder head and the top of each valve lifter.

    2. A0119APE02
      Text in Illustration
      *1 Paint Mark
      *2 Timing Mark

      Align the matchmarks on the timing chain plates with the timing mark of the camshaft timing sprocket assembly and the paint mark of the timing chain respectively and install the timing chain.

  3. INSTALL NO. 2 CAMSHAFT


    1. Apply engine oil to each cam of the No. 2 camshaft.

    2. A0118MWE02
      Text in Illustration
      *1 No. 1 Camshaft
      *2 No. 2 Camshaft
      *3 No. 3 Cylinder
      *4 No. 1 Cylinder
      *5 No. 2 Cylinder

      Install the camshafts as shown in the illustration.

      Tech Tips

      Make sure that the timing marks of the camshaft timing sprocket and camshaft timing sprocket face upward.

    3. A0118QUE02
      Text in Illustration
      *1 No. 1 Camshaft Bearing Cap
      *2 No. 2 Camshaft Bearing Cap

      Place the No. 1 camshaft bearing cap and No. 2 camshaft bearing caps and tighten the bolts to the specified torque in the order shown in the illustration.

      Torque:
      No. 1 camshaft bearing cap
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }
      No. 2 camshaft bearing cap
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

      Note

      Install No. 1 camshaft bearing cap and No. 2 camshaft bearing caps with the front marks facing engine front.

  4. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET

    A0117GOE02

    1. Align the matchmarks on the timing chain plates with the timing mark of the camshaft timing gear or sprocket and the paint mark of the timing chain respectively and install the timing chain.

      Text in Illustration
      *1 Paint Mark
      *2 Timing Mark
    2. A011BT5

      Install the No. 2 camshaft with the knock pin aligned with the gear groove.

      Tech Tips

      Position the timing mark of the gear at the top.

    3. A01186DE02

      Tighten the bolts onto the timing gear while holding the hexagonal portion of the No. 2 camshaft.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }

  5. INSTALL CAMSHAFT TIMING SPROCKET ASSEMBLY

    A0117MDE02

    1. Tighten the bolts onto the sprocket while holding the hexagonal portion of the camshaft.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }

  6. INSTALL TIMING GEAR COVER TIGHT PLUG


    1. Remove the hexagon wrench from the timing chain tensioner sub-assembly.

      Tech Tips

      Before removing, slightly turn the hexagonal portion of the camshaft assembly counterclockwise to leave some slack on the chain of the timing chain tensioner sub-assembly side.

    2. A0119GQE01
      Text in Illustration
      *1 Adhesive

      Clean the plug and the bolt holes of the timing chain cover and apply adhesive to the threads of the plug.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. A011AY2

      Using an 8 mm socket hexagon wrench, install the timing gear tight plug.

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

  7. INSPECT VALVE CLEARANCE

    A01183KE01
    Text in Illustration
    *1 Intake Side
    *2 Exhaust Side

    1. Check only the valves indicated.


      1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

        Valve clearance (Cold)
        Intake side
        0.145 to 0.235 mm (0.00571 to 0.00925 in.)
        Exhaust side
        0.275 to 0.365 mm (0.01083 to 0.01437 in.)

        Tech Tips

        Insert the feeler gauge from the spark plug side (center).

      2. Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifters.

    2. Turn the crankshaft 1 revolution (360°).

    3. A01196TE01
      Text in Illustration
      *1 Intake Side
      *2 Exhaust Side

      Check only the valves indicated.


      1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

        Valve clearance (Cold)
        Intake side
        0.145 to 0.235 mm (0.00571 to 0.00925 in.)
        Exhaust side
        0.275 to 0.365 mm (0.01083 to 0.01437 in.)

        Tech Tips

        Insert the feeler gauge from the spark plug side (center).

      2. Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifters.

  8. ADJUST VALVE CLEARANCE


    1. Remove the No. 1 and No. 2 camshafts Click here.

    2. Remove the valve lifters Click here.

    3. A011AP9

      Using a micrometer, measure the thickness of the removed valve lifters.

    4. Calculate the thickness of a new lifter so that the valve clearance comes within the specified value.

      A Thickness of new lifter
      B Thickness of used lifter
      C Measured valve clearance
      Valve clearance
      Intake A = B + (C - 0.18 mm (0.0071 in.))
      Exhaust A = B + (C - 0.31 mm (0.0122 in.))

      Tech Tips


      • Select a new lifter with a thickness as close to the calculated values as possible.

      • Lifters are available in 29 sizes in increments of 0.020 mm (0.0008 in.), from 5.12 mm (0.2016 in.) to 5.68 mm (0.2236 in.).

      • Refer to the New Lifter Thickness Table on the next 2 pages.

    5. Install the valve lifters Click here.

    6. Install the No. 1 and No. 2 camshafts Click here.

      A011BOCE01
      A011BGGE02

      Tech Tips

      New Lifter Thickness mm (in.)
      Lifter No. Thickness Lifter No. Thickness Lifter No. Thickness
      12 5.12 (0.2016) 32 5.32 (0.2094) 52 5.52 (0.2173)
      14 5.14 (0.2024) 34 5.34 (0.2102) 54 5.54 (0.2181)
      16 5.16 (0.2031) 36 5.36 (0.2110) 56 5.56 (0.2189)
      18 5.18 (0.2039) 38 5.38 (0.2118) 58 5.58 (0.2197)
      20 5.20 (0.2047) 40 5.40 (0.2126) 60 5.60 (0.2205)
      22 5.22 (0.2055) 42 5.42 (0.2134) 62 5.62 (0.2213)
      24 5.24 (0.2063) 44 5.44 (0.2142) 64 5.64 (0.2220)
      26 5.26 (0.2071) 46 5.46 (0.2150) 66 5.66 (0.2228)
      28 5.28 (0.2079) 48 5.48 (0.2157) 68 5.68 (0.2236)
      30 5.30 (0.2087) 50 5.50 (0.2165) - -

  9. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    A011A1E

    1. Clean the cylinder head cover, cylinder head assembly and timing chain cover assembly.

    2. Fit the cylinder head cover gasket into the gasket groove on the cover and onto the center bosses.

    3. A011AO5E01

      Apply a continuous bead of seal packing (diameter: 3 to 4 mm (0.118 to 0.157 in.)) to the contact surface between the cylinder head assembly and timing chain cover assembly, as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
    4. A011B65E01
      Text in Illustration
      *1 Bolt A
      *2 Bolt B

      Tighten the bolts A, and then the bolts B.

      Note

      After tightening all of the bolts, check that the bolts A meet the specified torque.

      Torque:
      7.7 N*m  { 79 kgf*cm, 68 in.*lbf }

    5. Install the wire harness to the cylinder head cover sub-assembly.

    6. A0118KT

      Connect the vacuum switching valve connector.

    7. A0118EX

      Connect the vacuum hose to the vacuum switching valve.

  10. INSTALL OIL FILLER CAP SUB-ASSEMBLY

    A01171C

    1. Install the oil filler cap sub-assembly.

  11. INSTALL HARNESS BRACKET


    1. Install the harness bracket with the bolt.

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

  12. INSTALL WATER FILLER ASSEMBLY


    1. Install the water filler assembly with the bolt.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }
    2. A01175Q

      Connect the No. 1 radiator hose and No. 3 radiator hose with the 2 clips.

  13. CONNECT RADIATOR RESERVOIR TANK HOSE

    A01187JE01

    1. Connect the radiator reservoir tank hose with the clip.

      Tech Tips

      Install the clip as shown in the illustration.

  14. INSTALL NO. 1 IGNITION COIL

    A011ANA

    1. Install the 3 No. 1 ignition coils with the 3 bolts.

      Torque:
      9.0 N*m  { 91 kgf*cm, 80 in.*lbf }

    2. Connect the 3 No. 1 ignition coil connectors.

  15. INSTALL INTAKE MANIFOLD

    Click here

  16. INSTALL NO. 1 ENGINE COVER

    A0118W1E01

    1. Temporarily install the No. 1 engine cover with the 2 bolts and nut.

    2. Fully tighten the 2 bolts and nut in the order shown in the illustration.

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

  17. INSTALL NO. 3 ENGINE UNDER COVER

    A0118DM

    1. Install the No. 3 engine under cover with the 3 clips.

  18. CHECK FOR ENGINE OIL LEAKAGE