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.



  1. INSTALL VALVE LASH ADJUSTER ASSEMBLY

    Note


    • Keep the valve lash adjuster assembly free from dirt and foreign objects.

    • Only use clean engine oil.

    • If the valve lash adjuster assembly is tilted after bleeding, oil will leak. Make sure to bleed the valve lash adjuster assembly again.


    1. Bleed the valve lash adjuster assembly Click here.

    2. If the plunger moves, bleed the valve lash adjuster assembly again.

    3. Place the valve lash adjuster assembly into a container full of new engine oil, and then fill the low pressure chamber with engine oil.

    4. Apply engine oil to the outer surface of the valve lash adjuster body and the tip of the plunger, and then install the valve lash adjuster assembly while turning it.

      Note

      Install the valve lash adjuster assembly to the same place it was removed from.

  2. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


    1. Apply engine oil to the valve lash adjuster assembly tips and valve stem caps.

    2. A01FSTDE08
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap

      Install the 16 No. 1 valve rocker arm sub-assemblies as shown in the illustration.

      Note

      Install the No. 1 valve rocker arm sub-assembly to the same place it was removed from.

  3. INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean the No. 2 camshaft bearing.

      Note

      Do not apply engine oil to the No. 2 camshaft bearing or contact surfaces.

    2. Install the No. 2 camshaft bearing to the camshaft housing sub-assembly.

    3. A01FRMTE02
      Text in Illustration
      *1 Camshaft Housing Sub-assembly
      *2 No. 2 Camshaft Bearing
      *a Vernier Caliper

      Using a vernier caliper, measure the distance between the camshaft housing sub-assembly edge and the No. 2 camshaft bearing edge.

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

  4. INSTALL NO. 2 CAMSHAFT

    Tech Tips

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



    1. Clean the No. 2 camshaft journals and camshaft housing sub-assembly.

    2. Apply a light coat of engine oil to the No. 2 camshaft journals and camshaft housing sub-assembly.

    3. Set the No. 2 camshaft to the camshaft housing sub-assembly.

  5. INSTALL CAMSHAFT

    Tech Tips

    Perform "Inspection After Repair" after replacing the camshaft.



    1. Clean the camshaft journals and camshaft housing sub-assembly.

    2. Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly.

    3. Set the camshaft to the camshaft housing sub-assembly.

  6. INSTALL NO. 1 CAMSHAFT BEARING


    1. Clean the No. 1 camshaft bearing.

      Note

      Do not apply engine oil to the No. 1 camshaft bearing or contact surfaces.

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

    3. A01FU6CE02
      Text in Illustration
      *1 No. 1 Camshaft Bearing Cap
      *2 No. 1 Camshaft Bearing
      *a Vernier Caliper

      Using a vernier caliper, measure the distance between the No. 1 camshaft bearing cap edge and the No. 1 camshaft bearing edge.

      Standard dimension
      A - B or B - A = 0 to 0.7 mm (0 to 0.0276 in.)

  7. INSTALL OIL CONTROL VALVE FILTER


    1. Check that there is no foreign matter on the mesh section.

    2. A01FQXD

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

      Note

      Do not touch the mesh section on the oil control valve filter.

  8. INSTALL CAMSHAFT BEARING CAP


    1. Clean the camshaft bearing caps.

    2. Apply a light coat of engine oil to the camshaft journals and camshaft bearing caps.

    3. Install the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap.

    4. A01FV6RE04
      Text in Illustration
      *1 No. 1 camshaft bearing cap
      *2 No. 2 camshaft bearing cap
      *3 No. 3 camshaft bearing cap
      *4 No. 4 camshaft bearing cap

      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 }

      Note

      After installing the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap, make sure that the camshaft and No. 2 camshaft rotate smoothly.

  9. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A01FR47E02
      Text in Illustration
      *a Seal Packing

      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
      3.0 to 4.0 mm (0.118 to 0.157 in.)

      Note


      • Remove any oil from the contact surface.

      • Check the bolts and bolt holes and clean them.

      • Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

      • Do not add engine oil within 2 hours of installation.

      • Do not start the engine for at least 2 hours after the installation.

    2. A01FSJQE07
      Text in Illustration
      *a Approximately 17°
      *b Approximately 2°
      *c Knock Pin

      Position the knock pin of the camshaft and No. 2 camshaft as shown in the illustration.

    3. A01FSTDE08
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap

      Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.

    4. A01FSQVE01

      Install the camshaft housing sub-assembly, and then tighten the 20 bolts in the order shown in the illustration.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }
      Standard Bolt
      Item Length
      Bolt A 70 mm (2.76 in.)
      Bolt B 45 mm (1.77 in.)
      Text in Illustration
      A01FTNO Bolt A
      A01FRJI Bolt B

      Note

      If the bolts have been loosened during the installation, apply seal packing black to the camshaft housing sub-assembly again.

  10. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. Secure the camshaft between aluminum plates in a vise.

      Note

      Do not damage the camshaft.

    2. Install the camshaft timing gear assembly to the camshaft Click here.

    3. Check the lock of the camshaft timing gear assembly.


      1. A01FVSEE02
        Text in Illustration
        *a Lock Pin Released
        *b Lock Pin Locked
        *c Pin Hole
        *d Lock Check Point

        Make sure that the camshaft timing gear assembly is locked.

    4. Release the lock pin.


      1. A01FQEUE02
        Text in Illustration
        *a Retard Side Path
        *b Advance Side Path
        *c Open
        *d Close
        *e Knock Pin
        A01FRLL Rubber Piece
        A01FTRV Vinyl Tape

        Clean the camshaft journal with non-residue solvent.

      2. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

        Tech Tips

        There are 4 oil paths in the grooves of the camshaft. Plug 3 of the paths with pieces of rubber.

      3. Open a hole at port A shown in the illustration.

      4. A01FVFI

        While applying approximately 200 kPa (2.0 kgf/cm2, 29 psi) of air pressure to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

        Note


        • Cover the paths with a piece of cloth when applying pressure to keep oil from spraying.

        • Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

        Tech Tips


        • The camshaft timing gear assembly may be turned in the advance direction without applying any force.

        • If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.

    5. Check for smooth rotation.


      1. Turn the camshaft timing gear assembly within its movable range (26.5 to 28.5°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly.

        Note

        Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

    6. Remove the vinyl tape and rubber pieces from the camshaft.

    7. Remove the bolt and camshaft timing gear assembly Click here.

    8. Place the chain sub-assembly around the camshaft timing gear assembly.

    9. Inspect the camshaft timing gear assembly diameter.


      1. A01FRSRE03
        Text in Illustration
        *a Chain Roller

        Using a vernier caliper, measure the camshaft timing gear assembly diameter with the chain sub-assembly.

        Minimum diameter (with chain sub-assembly)
        115.12 mm (4.53 in.)

        Tech Tips

        The vernier caliper must contact the chain rollers for the measurement.

        If the diameter is less than the minimum, replace the chain sub-assembly and camshaft timing gear assembly.

  11. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    Tech Tips

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



    1. When using a new camshaft timing gear assembly:


      1. A01FVSEE02
        Text in Illustration
        *a Lock Pin Released
        *b Lock Pin Locked
        *c Pin Hole
        *d Lock Check Point

        Check that the camshaft timing gear assembly is not locked.

        Note

        If locked, release the lock pin of the camshaft timing gear assembly Click here.

    2. A01FRHNE02
      Text in Illustration
      *a Pin Hole
      *b Knock Pin

      When reusing the camshaft timing gear assembly:


      1. Release the lock pin Click here.

    3. Put the camshaft timing gear assembly and camshaft together by aligning the pin hole and knock pin.

    4. Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the knock pin enters the pin hole.

      Note


      • Be sure not to turn the camshaft timing gear assembly in the advanced direction.

      • Do not forcefully press the camshaft timing gear assembly. Otherwise, the tip of knock pin of the camshaft may damage the seal surface of the camshaft timing gear assembly, leading to poor sealing.

    5. A01FRKJE32
      Text in Illustration
      *1 Camshaft Timing Gear Assembly
      *a Incorrect
      *b Correct
      *c Clearance
      *d No Clearance
      *e Camshaft Flange

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

    6. A01FQ1KE01
      Text in Illustration
      *a Hold
      *b Turn

      Using a wrench to hold the hexagonal portion of the camshaft, tighten the bolt.

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

      Note


      • Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.

      • If the camshaft timing gear assembly has been locked at the most retarded position, release the lock pin first, and then tighten the bolt.

      • The lock pin may be damaged if the bolt is tightened when the camshaft timing gear assembly is locked.

  12. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. Secure the No. 2 camshaft between aluminum plates in a vise.

      Note

      Do not damage the No. 2 camshaft.

    2. Install the camshaft timing exhaust gear assembly to the No. 2 camshaft Click here.

    3. Release the lock pin.


      1. A01FSZPE02
        Text in Illustration
        *a Advance Side Path
        *b Retard Side Path
        *c Open
        *d Close
        *e Knock Pin
        A01FRLL Rubber Piece
        A01FTRV Vinyl Tape

        Clean the No. 2 camshaft journal with non-residue solvent.

      2. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

        Tech Tips

        There are 4 oil paths in the grooves of the No. 2 camshaft. Plug 2 paths with rubber pieces.

      3. Make a hole in the vinyl tape placed over the 2 oil holes that are not plugged with rubber pieces.

      4. A01FQMUE06
        Text in Illustration
        *a Advance Side Path
        *b Retard Side Path

        Apply approximately 200 kPa (2.0 kgf/cm2, 29 psi) of air pressure to the 2 open paths (the advance side path and retard side path).

        Note

        Cover the paths with a piece of cloth when applying pressure to keep oil from spraying.

      5. A01FTIBE05
        Text in Illustration
        *a Advance Side Path
        *b Retard Side Path
        *c Hold Pressure
        *d Decompress

        Check that the camshaft timing exhaust gear assembly turns in the retard direction when reducing the air pressure applied to the advance side path.

        Tech Tips

        The lock pin is released and the camshaft timing exhaust gear assembly turns in the retard direction.

      6. When the camshaft timing exhaust gear assembly moves to the most retarded position, release the air pressure from the advance side path, and then release the air pressure from the retard side path.

        Note

        Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear assembly may abruptly shift in the advance direction and break the lock pin or other parts.

    4. Check for smooth rotation.


      1. Turn the camshaft timing exhaust gear assembly within its movable range (21.5 to 23.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear turns smoothly.

        Note

        When the air pressure is released from the advance side path and then from the retard side path, the gear automatically returns to the most advanced position due to the advance assist spring operation, and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check.

    5. Remove the vinyl tape and rubber pieces from the No. 2 camshaft.

    6. Remove the bolt and camshaft timing exhaust gear assembly Click here.

    7. Place the chain sub-assembly around the camshaft timing exhaust gear assembly.

    8. Inspect the camshaft timing exhaust gear assembly diameter.


      1. A01FVSUE03
        Text in Illustration
        *a Chain Roller

        Using a vernier caliper, measure the camshaft timing exhaust gear assembly diameter with the chain sub-assembly.

        Minimum diameter (with chain sub-assembly)
        115.12 mm (4.53 in.)

        Tech Tips

        The vernier caliper must contact the chain rollers for the measurement.

        If the diameter is less than the minimum, replace the chain sub-assembly and camshaft timing exhaust gear assembly.

  13. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Tech Tips

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



    1. A01FUD7E15
      Text in Illustration
      *a Pin Hole
      *b Knock Pin

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

      Note

      Do not forcefully press the camshaft timing exhaust gear assembly. Otherwise, the tip of knock pin of the No. 2 camshaft may damage the seal surface of the camshaft timing exhaust gear assembly, leading to poor sealing.

    2. A01FRKJE32
      Text in Illustration
      *1 Camshaft Timing Exhaust Gear Assembly
      *a Incorrect
      *b Correct
      *c Clearance
      *d No Clearance
      *e Camshaft Flange

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

    3. A01FUP1E01
      Text in Illustration
      *a Hold
      *b Turn

      Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the bolt.

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

      Note

      Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.

  14. POUR ENGINE OIL

    Note


    • Oil must be added if the valve lash adjuster assemblies or No. 1 valve rocker arm sub-assemblies were removed.

    • Make sure that the oil passage is full of engine oil.


    1. A01FVW5

      Pour 100 cc (6.1 cu. in.) of engine oil into the oil hole shown in the illustration.

  15. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A01FUGGE01

      Install the No. 1 chain vibration damper by tightening the 2 bolts in the order shown in the illustration.

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

  16. INSTALL CHAIN SUB-ASSEMBLY


    1. Temporarily install the crankshaft pulley set bolt.

    2. A01FSPYE01

      Rotate the crankshaft 40° counterclockwise.

    3. A01FQU6E02
      Text in Illustration
      *a Timing Mark
      *b Identification Groove
      *c Approximately 7°
      *d Approximately 32°

      Check that the timing marks of the camshaft timing gears are as shown in the illustration.

      Tech Tips

      The camshaft timing gear assembly and the camshaft timing exhaust gear assembly have both timing marks and identification grooves. Use the timing marks for alignment.

    4. Place the chain sub-assembly onto the camshaft timing gears and crankshaft timing gear or sprocket.

      Note


      • Make sure the mark plate of the chain sub-assembly faces away front of the engine.

      • It is not necessary to install the chain sub-assembly to the teeth of the camshaft timing gears and crankshaft timing gear or sprocket.

    5. A01FR76E02
      Text in Illustration
      *a Mark Plate (Orange)
      *b Timing Mark

      Align the mark plate (orange) of the chain sub-assembly with the timing mark of the camshaft timing exhaust gear assembly and install the chain sub-assembly to the camshaft timing exhaust gear assembly.

    6. A01FUZ0E02
      Text in Illustration
      *a Mark Plate (Yellow)
      *b Timing Mark

      Align the mark plate (yellow) of the chain sub-assembly with the timing mark of the crankshaft timing gear or sprocket and install the chain sub-assembly to the crankshaft timing gear or sprocket.

    7. A01FQ0BE02
      Text in Illustration
      *a String

      Tie the chain sub-assembly with a string above the crankshaft timing gear or sprocket to secure the chain sub-assembly.

    8. A01FQ44E02
      Text in Illustration
      *a Mark Plate (Orange)
      *b Timing Mark

      Using the hexagonal portion of the camshaft, rotate the camshaft counterclockwise with a wrench.

      Align the timing mark of the camshaft timing gear assembly with the mark plate (orange) of the chain sub-assembly and install the chain sub-assembly to the camshaft timing gear assembly.

      Tech Tips

      Hold the camshaft in place with a wrench until the No. 1 chain tensioner assembly is installed.

    9. A01FRSC

      Remove the string above the crankshaft timing gear or sprocket, rotate the crankshaft clockwise, and loosen the chain sub-assembly so that the chain tensioner slipper can be installed.

      Note

      Make sure that the chain sub-assembly is securely installed.

  17. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper with the bolt.

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

  18. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. Install a new chain tensioner gasket and the No. 1 chain tensioner assembly with the 2 bolts.

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

    2. Remove the pin from the stopper plate.

    3. A01FVSEE02
      Text in Illustration
      *a Lock Pin Released
      *b Lock Pin Locked
      *c Pin Hole
      *d Lock Check Point

      Rotate the camshaft counterclockwise, and then check that the camshaft timing gear assembly locks at the most retarded position.

      Note

      If the camshaft timing gear assembly is not locked, make sure to lock it securely.

  19. INSTALL TIMING CHAIN GUIDE


    1. Install the timing chain guide with the bolt.

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

  20. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley set bolt.

    2. Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear or sprocket and camshaft timing gears are positioned as shown in the illustration.

      A01FU0NE02
      Text in Illustration
      *1 Crankshaft Pulley Set Crankshaft Key - -
      *a Timing Mark *b Identification Groove
      *c Approximately 7° *d Approximately 32°

      Tech Tips


      • The camshaft timing gear assembly and the camshaft timing exhaust gear assembly have both timing marks and identification grooves. Use the timing marks for alignment.

      • If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks.

    3. Remove the crankshaft pulley set bolt.

  21. INSTALL TIMING CHAIN COVER ASSEMBLY

    Click here