CAMSHAFT INSTALLATION

INSTALL VALVE LASH ADJUSTER ASSEMBLY
1. Inspect each valve lash adjuster before installing it Click here.
2. Install the 16 valve lash adjusters to the cylinder head.
  
  Note
  
  Install the valve lash adjuster to the same place it was removed from.

INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

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

Apply engine oil to the valve lash adjuster tips and valve stem cap ends.

Make sure that the No. 1 valve rocker arms are installed as shown in the illustration.

INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

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

Check that the valve rocker arms are installed as shown in the illustration.

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

Area	Specified Condition
Continuous line	3.5 to 4.5 mm (0.138 to 0.177 in.)
A	8.0 mm (0.315 in.)
B	7.0 mm (0.276 in.)

Application Length A and B
15 mm (0.591 in.)

Note

Remove any oil from the contact surfaces.
Install the camshaft housing within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installation.

Set the camshaft and No. 2 camshaft as shown in the illustration.
Install the camshaft housing with the 17 bolts and tighten them in the order shown in the illustration.

Torque:

27 N*m { 275 kgf*cm, 20 ft.*lbf }
Note
- After installing the camshaft housing, make sure that the cam lobes are positioned as shown in the illustration.
- If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
- If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
- After installing the camshaft housing, wipe off any seal packing that seeped out from between the housing and cylinder head.

INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
1. Text in Illustration
  
  *1 Straight Pin
  
  *2 Pin Hole
  
  Put the camshaft timing exhaust gear and camshaft together by aligning the pin hole and straight pin.
  
  Note
  
  Do not forcefully push in the camshaft timing exhaust gear. This may cause the camshaft straight pin tip to damage the installation surface of the camshaft timing exhaust gear.
2. Lightly press the gear against the camshaft and turn the gear. Push further at the position where the pin enters the hole.
  
  Note
  
  Be sure not to turn the camshaft timing exhaust gear in the retard direction (clockwise).
3. Check that there is no clearance between the gear and camshaft flange.
4. Tighten the flange bolt with the camshaft timing exhaust gear secured in place.
  
  Torque:
  
  54 N*m { 551 kgf*cm, 40 ft.*lbf }
5. Check the camshaft timing exhaust gear lock.
  1. Make sure that the camshaft timing exhaust gear is locked.
INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
1. Text in Illustration
  
  *1 Straight Pin
  
  *2 Key Groove
  
  Put the camshaft timing gear 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. This may cause the camshaft straight pin tip to damage the installation surface of the camshaft timing gear.
2. Text in Illustration
  
  *1 Straight Pin
  
  *2 Key Groove
  
  Turn the camshaft timing gear as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.
  
  Note
  
  Do not turn the camshaft timing gear in the retard direction (clockwise).
3. Check that there is no clearance between the camshaft timing gear and camshaft flange.
4. Tighten the flange bolt with the camshaft timing gear secured in place.
  
  Torque:
  
  54 N*m { 551 kgf*cm, 40 ft.*lbf }
5. Text in Illustration
  
  *1 Lock
  
  Check that the camshaft timing gear can move in the retard direction (clockwise) and is locked in the most retarded position.
INSTALL NO. 1 CHAIN VIBRATION DAMPER
1. Install the chain vibration damper with the 2 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
SET NO. 1 CYLINDER TO TDC/COMPRESSION
1. Text in Illustration
  
  *1 Timing Gear Key
  
  Temporarily install the crankshaft pulley bolt.
2. Turn the crankshaft counterclockwise to position the timing gear key at the top.
3. Text in Illustration
  
  *1 Timing Mark
  
  Check that the timing marks on the camshaft timing gears are aligned as shown in the illustration.
4. Remove the crankshaft pulley bolt.
INSTALL CHAIN SUB-ASSEMBLY
1. Text in Illustration
  
  *1 Mark Plate (Orange)
  
  *2 Timing Mark
  
  Align the mark plate (orange) with the timing mark as shown in the illustration and install the chain.
  Tech Tips
  - Be sure to position the mark plate at the front of the engine.
  - The mark plate on the camshaft side is colored orange.
  - Do not pass the chain around the sprocket of the camshaft timing gear. Only place it on the sprocket.
  - Pass the chain through the No. 1 vibration damper.
2. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear counterclockwise to align the mark plate (orange) and timing mark, and then install the chain.
3. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear clockwise.
  
  Tech Tips
  
  To tension the chain, slowly turn the camshaft timing gear clockwise to prevent the chain from being misaligned.
4. Text in Illustration
  
  *1 Timing Mark
  
  *2 Mark Plate (Pink)
  
  Align the mark plates (pink) and timing marks and install the chain to the crankshaft timing gear.
  
  Tech Tips
  
  The mark plates on the crankshaft side are colored pink.
INSTALL CHAIN TENSIONER SLIPPER
1. Install the chain tensioner slipper to the cylinder block.

Text in Illustration
*1	Straight Pin
*2	Pin Hole

Text in Illustration
*1	Straight Pin
*2	Key Groove

Text in Illustration
*1	Straight Pin
*2	Key Groove

Text in Illustration
*1	Lock

Text in Illustration
*1	Timing Gear Key

Text in Illustration
*1	Timing Mark

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

Text in Illustration
*1	Timing Mark
*2	Mark Plate (Pink)

CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

Check each timing mark at TDC/compression.

Text in Illustration
*1	Timing Mark	*2	Mark Plate (Orange)
*3	Mark Plate (Pink)	-

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

Install a new gasket.

Note

Remove any oil from the contact surface.
Install the water pump with the 3 bolts.

Torque:

24 N*m { 241 kgf*cm, 17 ft.*lbf }
Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head, camshaft housing, stiffening crankcase and cylinder block.
Install 3 new O-rings.
Apply seal packing as shown in the illustration.

Seal packing

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

Standard seal diameter

5.0 mm (0.197 in.)
Note
- Remove any oil from the contact surface.
- Install the timing chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
- Do not add engine oil for at least 2 hours after installing the timing chain cover.

Standard seal diameter
5.0 mm (0.197 in.)

Apply seal packing to the timing chain cover in a continuous line as shown in the following illustration.

Seal Packing

Item	Seal Packing
Dashed line	Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Continuous line
Alternate long and short dashed line	Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

Application Specification

Area	Seal Packing Diameter	Distance from Edge of Cover to:	Seal Packing Application Length	Distance from Top of Cover to Top of Seal Packing
Dashed line	2.5 to 3.0 mm (0.0984 to 0.118 in.)	Center of seal packing 2.5 mm (0.0984 in.)	-	-
Continuous line	4.5 to 5.5 mm (0.177 to 0.217 in.) or 7.0 to 8.0 mm (0.276 to 0.315 in.)	-	-	-
Alternate long and short dashed line	4.0 mm (0.157 in.)	Center of seal packing 3.0 mm (0.118 in.)	-	-
A - A	2.5 to 3.0 mm (0.0984 to 0.118 in.)	Center of seal packing 2.5 mm (0.0984 in.)	-	-
B - B	4.5 to 5.5 mm (0.177 to 0.217 in.)	Opposite edge of seal packing 5.0 mm (0.197 in.)	-	-
C - C	7.0 to 8.0 mm (0.276 to 0.315 in.)	Opposite edge of seal packing 7.5 mm (0.295 in.)	-	-
F	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	15.5 mm (0.610 in.)	50.4 mm (1.98 in.)
G	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	10.3 mm (0.406 in.)	143.1 mm (5.63 in.)
H	7.0 to 8.0 mm (0.276 to 0.315 in.)	-	19.5 mm (0.768 in.)	153.4 mm (6.04 in.)
I	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	16.0 mm (0.630 in.)	385.8 mm (1.27 ft.)
J	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	18.6 mm (0.732 in.)	51.4 mm (2.02 in.)
K	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	25.3 mm (0.996 in.)	121.9 mm (4.80 in.)
L	7.0 to 8.0 mm (0.276 to 0.315 in.)	-	25.8 mm (1.02 in.)	147.2 mm (5.80 in.)
M	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	5.1 mm (0.201 in.)	173.0 mm (6.81 in.)
N	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	14.6 mm (0.575 in.)	385.8 mm (1.27 ft.)
O	4.0 mm (0.157 in.)	Center of seal packing 3.0 mm (0.118 in.)	-	-

Note

When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing.
Install the timing chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
After applying seal packing to the timing chain cover, install the engine mounting bracket and oil filter bracket within 10 minutes.
Do not add engine oil for at least 2 hours after installation.

Clean the bolts and their installation holes.
Install the timing chain cover.
Temporarily install the engine mounting bracket with the 3 bolts.
Note
- Install the mounting bracket within 10 minutes after installing the timing chain cover.
- Do not add engine oil for at least 2 hours after installation.
Install 2 new O-rings.
Temporarily install the oil filter bracket with the 4 bolts.
Note
- Install the oil filter bracket within 10 minutes after installing the timing chain cover.
- Do not add engine oil for at least 2 hours after installation.
Text in Illustration

*1 Adhesive

Apply adhesive to 5 and a half threads or more of the end of bolt E.

Adhesive

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Text in Illustration
*1	Adhesive

Adhesive
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Install the timing chain cover with the 26 bolts and seal washer in the order shown in the illustration.

Torque:: for bolt A, E; 26 N*m { 260 kgf*cm, 19 ft.*lbf }; for bolt B; 51 N*m { 520 kgf*cm, 38 ft.*lbf }; for bolt C; 51 N*m { 520 kgf*cm, 38 ft.*lbf }; for bolt D; 10 N*m { 102 kgf*cm, 7 ft.*lbf }

Note

When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing.
Install the timing chain cover within 3 minutes and tighten the bolts within 10 minutes after applying the seal packing.
Do not add engine oil for at least 2 hours after installation.

Bolt Length

Item	Length	Thread Diameter
Bolt A, E	35 mm (1.38 in.)	8 mm (0.315 in.)
Bolt B	55 mm (2.17 in.)	10 mm (0.394 in.)
Bolt C	80 mm (3.15 in.)	10 mm (0.394 in.)
Bolt D	40 mm (1.57 in.)	6 mm (0.236 in.)

Tech Tips

Apply adhesive to bolt E before installing it.

INSTALL TIMING CHAIN COVER OIL SEAL
1. Apply MP grease to the lip of a new oil seal.
  Note
  
  Do not allow foreign matter to contact the lip of the oil seal.
  
  Do not allow MP grease to contact the dust seal.
2. Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover edge.
  
  SST
  
  09223-22010
  Note
  - Wipe off any extra grease from the crankshaft.
  - Do not tap in the oil seal at an angle.
INSTALL CRANKSHAFT PULLEY
1. Text in Illustration
  
  *1 Hold
  
  *2 Turn
  
  Align the key groove of the pulley with the pulley set key.
2. Temporarily install the pulley with the pulley bolt.
3. Using SST, hold the pulley in place and tighten the bolt.
  
  SST
  
  09330-00021
  
  09213-58014 ( 91551-80840 )
  
  Torque:
  
  190 N*m { 1940 kgf*cm, 140 ft.*lbf }

Text in Illustration
*1	Hold
*2	Turn

INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

Release the cam, and then fully push in the plunger and engage the hook to the pin so that the plunger is in the position shown in the illustration.

Note

Make sure that the cam engages the first tooth of the plunger to allow the hook to pass over the pin.
Install a new gasket, the chain tensioner and bracket with the 2 nuts.

Torque:

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

Note

If the hook releases the plunger while the chain tensioner is being installed, set the hook again.

Text in Illustration
*1	Release
*2	Pin
*3	Hook
*4	Turn

Rotate the crankshaft counterclockwise slightly and check that the hook becomes released.

Text in Illustration
*1	Plunger
*2	Plunger Extended
*3	Turn

Turn the crankshaft clockwise and check that the plunger is extended.

INSTALL SPARK PLUG TUBE GASKET

Text in Illustration

*1 Part to Cut Off

Using a cutter knife, cut off the seal part of the removed gasket.

Text in Illustration
*1	Part to Cut Off

Text in Illustration
*1	Plug Tube Gasket without Sealing Part
*2	New Plug Tube Gasket
*3	Claw

Using a hammer and a plug tube gasket which has had the sealing part cut off, uniformly tap in a new plug tube gasket all the way.

Tech Tips

If a plug tube gasket that will be used to install a new gasket is deformed and cannot be positioned on a new gasket, correct the deformation using pliers.

Note

Keep the lip free of foreign matter.
Do not tap in the plug tube gasket at an angle.

Return the claws of the ventilation baffle plate to their original positions.

INSTALL CYLINDER HEAD COVER GASKET
1. Install a new cylinder head cover gasket to the cylinder head cover.
  
  Note
  
  Remove any oil from the contact surfaces.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
1. Install 3 new gaskets to the camshaft bearing cap.
2. Apply seal packing as shown in the illustration.
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Standard diameter
  
  4.0 mm (0.157 in.)
  Note
  
  Remove any oil from the contact surfaces.
  
  Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
  
  Do not start the engine for at least 2 hours after the installation.
3. Install the cylinder head cover with a new seal washer and the 13 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL RADIO SETTING CONDENSER
1. Install the setting condenser with the bolt.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }

Standard diameter
4.0 mm (0.157 in.)

INSTALL IGNITION COIL ASSEMBLY

Text in Illustration
*1	Cylinder Head Cover
*2	Spark Plug Tube
*3	Plug Cap

Install the 4 ignition coils with the 4 bolts.

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

Note

When installing the ignition coil, do not damage the plug cap with the cylinder head cover opening or the upper edge of the spark plug tube.

Connect the 4 ignition coil connectors.

INSTALL NO. 1 VACUUM PUMP BRACKET
1. Install a new gasket and the vacuum pump bracket with the 2 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL VACUUM PUMP ASSEMBLY
1. Apply engine oil to 2 new O-rings.
2. Install the 2 O-rings to the vacuum pump.
3. Text in Illustration
  
  *1 Engine oil
  
  Apply engine oil to the cylinder hollow.
4. Install the vacuum pump so that the coupling teeth of the vacuum pump (labeled A) and the grooves of the camshaft (labeled B) are aligned.
  
  Note
  
  Be careful not to damage the O-ring.
5. Install the vacuum pump with the 3 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  Note
  
  Confirm that the vacuum pump is not at an angle, and that there is no clearance between the fitting surfaces.
INSTALL THERMOSTAT
1. Install a new gasket to the thermostat.
2. Install the thermostat to the water inlet.
  
  Note
  
  The jiggle valve must be set within 10° on either side of the position shown in the illustration.
INSTALL WATER INLET
1. Install the water inlet with the 2 nuts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL WATER INLET HOSE
1. Install the water inlet hose with the 2 clamps.
CONNECT NO. 3 WATER BY-PASS HOSE
1. Connect the No. 3 water by-pass hose to the water inlet housing.
INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
1. Apply a light coat of engine oil to a new O-ring.
2. Install the O-ring to the dipstick guide.
3. Install the dipstick guide with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
4. Install the engine oil level dipstick.

Text in Illustration
*1	Engine oil

INSTALL FUEL INJECTOR ASSEMBLY

Text in Illustration
*1	O-Ring
*2	Injector Vibration Insulator

Install a new injector vibration insulator to the fuel injector.

Apply a light coat of gasoline or spindle oil to the contact surfaces of the O-ring of the fuel injector.
While turning the fuel injector left and right, install it to the fuel delivery pipe.
Note
- Do not twist the O-ring.
- After installing the fuel injectors, check that they turn smoothly. If not, replace the O-ring with a new one.

INSTALL NO. 1 DELIVERY PIPE SPACER
1. Install the 2 No. 1 delivery pipe spacers to the cylinder head.
  
  Note
  
  Install the No. 1 delivery pipe spacers in the correct direction.
INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
1. Install the fuel delivery pipe with the 4 fuel injector assemblies, and then temporarily install the 2 bolts.
  Note
  
  Do not drop the fuel injectors when installing the fuel delivery pipe.
  
  Check that the fuel injector assemblies rotate smoothly after installing the fuel delivery pipe.
2. Tighten the 2 bolts to the specified torque.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
3. Install the bolt to secure the fuel delivery pipe.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
4. Install the wire harness bracket with the bolt.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }

INSTALL FUEL TUBE SUB-ASSEMBLY

Text in Illustration
*1	Retainer
*2	Pipe
*3	O-Ring

Push the fuel tube sub-assembly connector onto the fuel delivery pipe until a "click" sound can be heard.

Note

Check that there are no scratches or foreign matter around the contact surfaces of the fuel tube connector and pipe before performing this step.
After connecting the fuel tube, check that the fuel tube connector and pipe are securely connected by pulling on them.

Text in Illustration

*1 Claw

Install a new No. 2 fuel pipe clamp.

INSTALL WIRE HARNESS CLAMP BRACKET
1. Install the wire harness clamp bracket with the 2 nuts.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
INSTALL AIR TUBE
1. Install the air tube with the 2 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Connect the No. 2 air hose and No. 1 fuel vapor feed hose.
3. Connect the 2 union to connector tube hoses.
4. Connect the fuel vapor feed hose to the purge VSV.
INSTALL INTAKE MANIFOLD
1. Using an E6 "TORX" socket wrench, install the 2 stud bolts to the intake manifold.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
2. Install the wire harness clamp bracket to the intake manifold with the bolt.
  
  Torque:
  
  15 N*m { 153 kgf*cm, 11 ft.*lbf }
3. Install a new gasket to the intake manifold.
4. Install the intake manifold and intake manifold stay with the 5 bolts and 2 nuts.
  
  Torque:
  
  28 N*m { 286 kgf*cm, 21 ft.*lbf }
5. Connect the fuel vapor feed hose and ventilation hose.
6. Attach the 5 clamps to the intake manifold.
7. Install the wire harness clamp bracket with the bolt.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL THROTTLE BODY ASSEMBLY
1. Install a new gasket to the intake manifold.
2. Install the throttle body with the 2 bolts and 2 nuts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
3. Connect the throttle body connector and 2 water hoses.
INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
1. Install the engine assembly with transaxle Click here.