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. A01EWCGE04
      Text in Illustration
      *1 Vernier Caliper

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

      Standard distance
      1.15 to 1.85 mm (0.0453 to 0.0728 in.)

  2. INSTALL NO. 1 CAMSHAFT BEARING


    1. A01EYOQE03
      Text in Illustration
      *1 Vernier Caliper

      Clean the No. 1 camshaft bearing.

    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. A01EWXX

      Install the oil control valve filter to the No. 1 camshaft bearing cap.

  4. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A01EYISE02
      Text in Illustration
      *1 Knock Pin Hole
      *2 Knock Pin

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

    2. A01ET3ZE10
      Text in Illustration
      *1 Camshaft Timing Exhaust Gear
      *2 Clearance
      *3 Camshaft Flange
      *a INCORRECT
      *b CORRECT
      *c No Clearance

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

    3. A01ETQB

      Fix the camshaft timing exhaust gear assembly with the bolt.

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

      Note

      Do not disassemble the camshaft timing exhaust gear.

      Tech Tips

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

  5. SET TDC/COMPRESSION


    1. A01ETSEE01
      Text in Illustration
      *1 Timing Notch

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

  6. INSTALL NO. 2 CAMSHAFT


    1. A01EU1CE06
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Valve Lash Adjuster
      *3 Valve Stem Cap

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

    2. Clean the camshaft journals.

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

    4. A01EXLHE01
      Text in Illustration
      *1 Paint Mark
      *2 Matchmark

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

      Tech Tips

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

  7. INSTALL CAMSHAFT


    1. A01EU1CE06
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Valve Lash Adjuster
      *3 Valve Stem Cap

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

    2. Clean the camshaft journals.

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

    4. A01ET5XE01
      Text in Illustration
      *1 Knock Pin
      *a Approximately 17°

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

      Tech Tips

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

  8. INSTALL CAMSHAFT BEARING CAP


    1. A01EXDL

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

    2. A01EUZHE02

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

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }
    3. A01ESPIE02

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

      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. A01EX0RE04
      Text in Illustration
      *1 Knock Pin Hole
      *2 Alignment Mark
      *a Advanced Position
      *b Retarded Position

      Check the camshaft timing gear position.

      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. A01EUSYE01
      Text in Illustration
      *a Narrow
      *b Wide

      Install the camshaft timing gear as shown in the illustration.

    3. A01EV4CE01
      Text in Illustration
      *a Narrow
      *b Wide

      Turn the camshaft timing gear approximately 180° counterclockwise.

    4. A01EWMDE01
      Text in Illustration
      *1 Paint Mark
      *2 Matchmark

      Align the paint mark with the matchmark to install the chain.

    5. A01EVVOE02
      Text in Illustration
      *1 Knock Pin Hole
      *2 Knock Pin

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

    6. A01ET3ZE10
      Text in Illustration
      *1 Camshaft Timing Gear
      *2 Clearance
      *3 Camshaft Flange
      *a INCORRECT
      *b CORRECT
      *c No Clearance

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

    7. Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear 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. A01EYV0E01
        Text in Illustration
        *1 Adhesive Tape Sealing Area
        *a Make a Hole

        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.

        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. A01EUAD

        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.

        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. A01EXZD

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

      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. A01ETVAE01
      Text in Illustration
      *1 Paint Mark
      *2 Matchmark

      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.

      Tech Tips

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

  10. ADD ENGINE OIL


    1. A01EV4U

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

      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. A01EV0O

      Install the timing chain guide with the bolt.

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

  12. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01EYS8E01

      Turn the crankshaft approximately 10° clockwise.

    2. A01EVE5

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

      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. A01EU8TE02
      Text in Illustration
      *1 Timing Mark
      *2 Timing Notch
      *a Approximately 7°
      *b Approximately 32°

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

    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. A01EWG1

      Install a new gasket and the timing chain cover plate with the 4 bolts.

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

  15. INSTALL TIMING CHAIN COVER TIGHT PLUG


    1. A01EWN1

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

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

  16. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01EV5L

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

    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. A01EU0SE03
      Text in Illustration
      *1 Seal Packing
      *2 Timing Chain Cover
      *3 Camshaft Housing

      Apply seal packing as shown in the illustration.

      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.)

      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. A01EUREE01

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

    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 4 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. A01EU9QE01

      Install the engine wire to the engine with the bolts and nuts.

      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. A01ETFOE01

      When the engine moving control rod has been replaced.


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

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

        Torque:
        38 N*m  { 387 kgf*cm, 28 ft.*lbf }
      3. A01ETQOE01

        Fully tighten the bolt A.

        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 bolt A using SST.

    2. A01EYTDE01

      When the engine moving control rod has been reused.


      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. A01EXCRE01
      Text in Illustration
      *a Wire harness clamp
      *b Hole
      *c Projection

      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.

    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

  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

    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 9 clips.

  32. INSTALL FRONT WHEEL RH