CAMSHAFT INSTALLATION


  1. INSTALL CAMSHAFT


    1. A0119H1E02
      Text in Illustration
      *1 TDC Mark
      *2 Key

      Turn the crankshaft to set the key in the 70° BTDC position.

    2. Apply engine oil to the camshaft journal portion and cam portion.

    3. A0119NLE01

      Examine the front marks and numbers and check that the sequence is as shown in the illustration. Then, temporarily tighten the camshaft with the camshaft bearing caps and bolts.

      Note

      Do not tilt the valve rocker arm when installing the camshaft onto the cylinder head.

    4. A011A20E01

      Using several steps, temporarily tighten the bolts in the sequence shown in the illustration, and then tighten the bolts to the specified torque.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  2. INSTALL CHAIN SUB-ASSEMBLY


    1. A0117M1E02
      Text in Illustration
      *1 Straight Pin

      Turn the camshaft to set the straight pin in the position shown in the illustration.

    2. A01193VE02
      Text in Illustration
      *1 TDC Mark
      *2 Key

      Turn the crankshaft to set the key in the position shown in the illustration.

    3. A011AT9E02
      Text in Illustration
      *1 Timing Mark
      *2 Orange Mark Plate
      *3 Yellow Mark Plate

      Align the chain's 2 orange mark plates with the timing mark on the camshaft timing sprocket, and the yellow mark plate with the timing mark on the crankshaft timing sprocket.

    4. A011AW0E02
      Text in Illustration
      *1 Timing Mark
      *2 Orange Mark Plate
      *3 Yellow Mark Plate

      Install the chain, camshaft timing sprocket and crankshaft sprocket together onto the engine.

    5. A011A1KE01

      Using SST, fix the camshaft timing sprocket, and install the camshaft timing sprocket with the 3 bolts.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  3. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A011A1I

      Install the chain vibration damper with the 2 bolts.

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

  4. INSTALL CHAIN TENSIONER SLIPPER


    1. A0118ZG

      Install the chain tensioner slipper onto the cylinder block.

  5. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A0118OSE01

      Push in the plunger until the groove is aligned with the tensioner hole, and then insert a 1.1 mm (0.043 in.) diameter bar.

    2. A011A5V

      Install the chain tensioner with the 2 bolts.

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

    3. Remove the 1.1 mm (0.043 in.) diameter bar from the chain tensioner.

    4. A0118FOE02
      Text in Illustration
      *1 Timing Mark
      *2 Orange Mark Plate
      *3 Yellow Mark Plate

      Check that the mark plate and timing mark are in the positions shown in the illustration.

  6. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. A0119BE

      Install the No. 2 timing chain cover with the clip.

  7. CONNECT WATER INLET HOSE LH

    A0119XW

    1. Connect the water inlet hose LH.

      Tech Tips

      The clip at the water inlet housing can be installed in any orientation, as long it does not contact any of the surrounding parts.

  8. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY


    1. Align the key with the key groove of the crankshaft damper, and slide the crankshaft damper to the crankshaft.

    2. A0119N2E01

      Using SST, secure the crankshaft damper.

      SST
      09213-58014
      09330-00021

    3. Tighten the bolt to the specified torque.

      Torque:
      210 N*m  { 2141 kgf*cm, 155 ft.*lbf }

  9. INSTALL NO. 2 TIMING CHAIN COVER


    1. A0119BE

      Install the No. 2 timing chain cover with the clip.

  10. INSTALL ENGINE MOUNTING BRACKET RH


    1. Temporarily tighten the engine mounting bracket with the 4 bolts.

    2. A0119XFE01

      Fully tighten the 4 bolts, as shown in the illustration.

      Torque:
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }

  11. CHECK VALVE CLEARANCE


    1. A011AYAE01
      Text in Illustration
      *1 Timing Mark
      *2 TDC Mark

      Set the No. 1 cylinder to TDC/Compression.


      1. Turn the crankshaft pulley until the grooves of the crankshaft damper and oil pump are aligned.

      2. Check that the timing mark of the camshaft timing sprocket is in the position shown in the illustration.

        Tech Tips

        If not, turn the crankshaft damper 1 revolution (360°) to align the timing mark and sprocket as above.

    2. A011BLOE03
      Text in Illustration
      *1 No. 1 Exhaust
      *2 No. 2 Intake
      *3 Camshaft
      *4 Feeler Gauge

      Check the valve clearance of the No. 1 cylinder exhaust valve and the No. 2 cylinder intake valve.


      1. Using a feeler gauge, measure the clearance between the camshaft and No. 1 valve rocker arm.

        Valve clearance (cold)
        0.11 to 0.17 mm (0.004 to 0.007 in.) for intake
        0.14 to 0.20 mm (0.006 to 0.008 in.) for exhaust

        Note


        • Insert the feeler gauge into the center of the roller surface, parallel to the No. 1 valve rocker arm.


        • Do not apply excessive force to the valve adjusting screw when using adjusting tools such as SST and a screwdriver.

        Tech Tips

        If the clearance is not as specified, record the out-of-specification measurement, and then adjust the valve clearance.

    3. A011742E02
      Text in Illustration
      *1 No. 1 Intake
      *2 No. 3 Exhaust
      *3 Camshaft
      *4 Feeler Gauge

      Check the valve clearance of the No. 1 cylinder intake valve and the No. 3 cylinder exhaust valve.


      1. Turn the crankshaft by a further 180° clockwise.

      2. Using a feeler gauge, measure the clearance between the camshaft and No. 1 valve rocker arm as shown in the illustration.

        Valve clearance (cold)
        0.11 to 0.17 mm (0.004 to 0.007 in.) for intake
        0.14 to 0.20 mm (0.006 to 0.008 in.) for exhaust

        Note


        • Insert the feeler gauge into the center of the roller surface, parallel to the No. 1 valve rocker arm.

        • Do not apply excessive force to the valve adjusting screw with adjusting tools when measuring or adjusting.

        Tech Tips

        If the clearance is not as specified, record the out-of-specification measurement, and then adjust the valve clearance.

    4. A0119M4E02
      Text in Illustration
      *1 No. 3 Intake
      *2 No. 4 Exhaust
      *3 Camshaft
      *4 Feeler Gauge

      Check the valve clearances of the No. 3 cylinder intake valve and No. 4 cylinder exhaust valve.


      1. Turn the crankshaft clockwise by a further 180°.

      2. Using a feeler gauge, measure the clearance between the camshaft and No. 1 valve rocker arm as shown in the illustration.

        Valve clearance (cold)
        0.11 to 0.17 mm (0.004 to 0.007 in.) for intake
        0.14 to 0.20 mm (0.006 to 0.008 in.) for exhaust

        Note


        • Insert the feeler gauge into the center of the roller surface, parallel to the No. 1 valve rocker arm.

        • Do not apply excessive force to the valve adjusting screw with adjusting tools when measuring or adjusting.

        Tech Tips

        If the clearance is not as specified, record the out-of-specification measurement, and then adjust the valve clearance.

    5. A0118CVE02
      Text in Illustration
      *1 No. 2 Exhaust
      *2 No. 4 Intake
      *3 Camshaft
      *4 Feeler Gauge

      Check the valve clearances of the No. 2 cylinder intake valve and No. 4 cylinder intake valve.


      1. Turn the crankshaft clockwise by a further 180°.

      2. Using a feeler gauge, measure the clearance between the camshaft and No. 1 valve rocker arm.

        Valve clearance (cold)
        0.11 to 0.17 mm (0.004 to 0.007 in.) for intake
        0.14 to 0.20 mm (0.006 to 0.008 in.) for exhaust

        Note


        • Insert the feeler gauge into the center of the roller surface, parallel to the No. 1 valve rocker arm.

        • Do not apply excessive force to the valve adjusting screw with adjusting tools when measuring or adjusting.

        Tech Tips

        If the clearance is not as specified, record the out-of-specification measurement, and then adjust the valve clearance.

  12. ADJUST VALVE CLEARANCE


    1. A01195FE02
      Text in Illustration
      *1 Adjusting Screw
      *2 Lock Nut

      Using SST and a screwdriver, loosen the valve adjusting nut while keeping the valve adjusting screw in position.

      SST
      09248-56010
    2. A0118URE02
      Text in Illustration
      *1 Adjusting Screw
      *2 Lock Nut
      *3 Feeler Gauge

      Adjust valve clearance (intake side).


      1. Insert a feeler gauge (0.14 mm (0.006 in.)) between the camshaft and No. 1 valve rocker arm, and turn the valve adjusting screw to adjust it.

        Valve clearance (cold)
        0.14 mm (0.006 in.)
      2. A0119NNE02
        Text in Illustration
        *1 Adjusting Screw
        *2 Lock Nut

        Using SST and a screwdriver, tighten the valve adjusting nut while keeping the valve adjusting screw in position.

        Torque:
        With SST
        13 N*m  { 133 kgf*cm, 10 ft.*lbf }
        Without SST
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

        Tech Tips


        • This torque wrench value can be obtained by using a torque wrench with a fulcrum length of 300 mm (11.81 in.) and SST with a fulcrum length of 150 mm (5.91 in.) Click here.

        • This torque value is effective when SST is parallel to a torque wrench.

    3. Adjust the valve clearance (exhaust side).

      Valve clearance (cold)
      0.17 mm (0.007 in.)

      Tech Tips

      Perform the same procedure as for the intake valve clearance adjustment.

  13. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Install the cylinder head gasket onto the cylinder head cover.

    2. A0118TYE01

      Apply seal packing to the 4 locations shown in the illustration, and then install the cylinder head cover.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surface.

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

    3. A011ABAE01

      Temporarily tighten the cylinder head cover with the 12 bolts.

    4. Fully tighten the 12 bolts, as shown in the illustration.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  14. INSTALL HARNESS BRACKET (w/o Air Conditioning System)

    A011AE6

    1. Install the harness bracket with the bolt.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

  15. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

    A0117ML

    1. Install the V-ribbed belt tensioner with the 2 bolts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  16. INSTALL IDLER PULLEY SUB-ASSEMBLY

    A01192A

    1. Install the idler pulley with the bolt.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  17. INSTALL VACUUM PUMP ASSEMBLY


    1. Install 2 new O-rings to the vacuum pump.

    2. A0118TC

      Install the vacuum pump with the 2 bolts.

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

  18. INSTALL CAMSHAFT POSITION SENSOR

    A0118LM

    1. Install the camshaft position sensor with the bolt.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Install the harness bracket with the bolt.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  19. INSTALL NO. 2 CYLINDER HEAD COVER

    A011756

    1. Install the No. 2 cylinder head cover.

    2. A0118GJ

      Install the 2 harness brackets with the 2 bolts.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  20. INSTALL OIL LEVEL DIPSTICK GUIDE


    1. Install a new O-ring to the oil level dipstick guide.

    2. A0119KF

      Install the oil level dipstick guide with the 2 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  21. INSTALL ENGINE OIL LEVEL DIPSTICK

  22. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Install a new O-ring to the water by-pass pipe.

    2. A01172XE01

      Install the water by-pass pipe with the 2 bolts, as shown in the illustration.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
    3. A011B8WE01

      Connect the water by-pass hose.

    4. A01174ME01

      Connect the oil cooler hose.

  23. INSTALL NO. 4 WATER BY-PASS HOSE

    A011A4OE01

    1. Install the No. 4 water by-pass hose.

  24. INSTALL NO. 2 OIL COOLER HOSE

    A01176FE02
    Text in Illustration
    *1 Paint Mark

    1. Install the No. 2 oil cooler hose.

      Note

      Align the oil cooler hose paint mark with the clamp center.

    2. A011BJSE02
      Text in Illustration
      *1 Paint Mark

      Install the hose clamp.

      Note

      Align the oil cooler hose paint mark with the clamp center.

  25. INSTALL SUPPLY PUMP DRIVE COUPLING


    1. A011909E03
      Text in Illustration
      *1 Camshaft
      *2 Supply Pump Drive Coupling
      *a Correct
      *b Incorrect

      Install the supply pump drive coupling into the camshaft.

      Note

      Install the supply pump drive coupling in the correct direction.

  26. TEMPORARILY TIGHTEN SUPPLY PUMP ASSEMBLY

    Note

    When installing, clean the seal surfaces of the fuel inlet pipe, supply pump and common rail.


    1. A0118J9

      Apply a light coat of engine oil to a new O-ring.

    2. Install the O-ring onto the supply pump.

    3. A0119GH

      Temporarily tighten the supply pump with the 3 bolts.

  27. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    A011ADSE01

    Note


    • When replacing the supply pump. the fuel inlet pipe must also be replaced.

    • Replace the fuel inlet pipe with a new one when the fuel inlet pipe has been removed and reinstalled more than 5 times.


    1. A011B6L

      Temporarily tighten the fuel inlet pipe onto the supply pump and common rail.

      Note

      Install the pipe and union nut vertically. not at a tilt.

    2. Fully tighten the supply pump with the 3 bolts.

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

    3. Using a union nut wrench (17 mm), tighten the fuel inlet pipe union nut on the common rail side.

      Torque:
      28 N*m  { 286 kgf*cm, 20 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    4. Using a wrench (17 mm), hold the supply pump nut, and using a union nut wrench (17 mm), tighten the fuel inlet pipe union nut on the supply pump side.

      Torque:
      28 N*m  { 286 kgf*cm, 20 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  28. CONNECT NO. 2 FUEL HOSE

    A011B0V

    1. Connect the No. 2 fuel hose.

  29. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY

    A011BDO

    1. Install the nozzle leakage pipe into each injector.


      1. Make sure the lock bush is at top position.

        A0119C7E01
        Text in Illustration
        *1 Lock Bush
        *2 Return Plug
        *3 Rest Arm
        *4 Injector

      2. Insert the rest arm into the injector and push both sides of the return plug until the rest arm engages with the injector, as shown in the illustration.

        Tech Tips

        Push the nozzle leakage pipe until it makes a click sound.

      3. Push the lock bush until the it fits with the return plug, as shown in the illustration.

    2. A0118JV

      Connect the nozzle leakage pipe and install new retainer spring onto the supply pump.

  30. INSTALL NOZZLE LEAKAGE PIPE SET CLAMP

    A011927

    1. Install the 3 nozzle leakage pipe set clamps.

  31. INSTALL NO. 2 INJECTION PIPE CLAMP


    1. A0118JH

      Install both sides of the No. 2 injection pipe clamp with the nut as shown in the illustration.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  32. INSTALL INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY


    1. Install the new gasket to the cylinder head.

    2. A0119J6

      Install the intake air connector with the diesel throttle body with the 2 bolts and 2 nuts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

  33. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. Install a new gasket.

    2. A0116YRE10
      Text in Illustration
      *1 Adhesive

      Apply adhesive to the 2 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
    3. A011BT6E02
      Text in Illustration
      *1 EGR Control Valve

      Install the electric EGR control valve with the 2 bolts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

    4. Connect the No. 3 water by-pass hose.

    5. Connect the No. 4 water by-pass hose.

  34. INSTALL HARNESS BRACKET

    A011AOS

    1. Install the harness bracket with the bolt.

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

    2. Connect the vacuum hose to the vacuum pump.

  35. INSTALL NO. 1 EGR COOLER BRACKET

    A01197G

    1. Install the No. 1 EGR cooler bracket with the 2 bolts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

    2. Connect the vacuum hose.

  36. INSTALL EGR WITH COOLER PIPE ASSEMBLY


    1. Install 2 new gaskets.

    2. A0119M3

      Install the EGR with cooler pipe assembly with the 4 bolts and 2 nuts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
    3. A011747E01

      Connect the No. 2 water by-pass hose.

    4. Connect the No. 2 oil cooler hose.

    5. Connect the 2 vacuum hoses and No. 1 oil hose.

    6. A0119C5E01

      Connect the No. 1 vacuum transmitting hose.

    7. Connect the vacuum transmitting hose.

  37. INSTALL GENERATOR BRACKET

    A011866

    1. Install the No. 1 generator bracket with the bolt.

      Torque:
      40 N*m  { 407 kgf*cm, 30 ft.*lbf }

  38. INSTALL GENERATOR ASSEMBLY

    A011BVOE01

    1. Install the generator with the 2 bolts and nut.

      Torque:
      Bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Bolt B, Nut
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

  39. INSTALL ENGINE ASSEMBLY


    1. Install the engine assembly Click here.