CAMSHAFT INSTALLATION


  1. SET CAMSHAFT TIMING GEAR ASSEMBLY

    Tech Tips

    When installing the camshaft timing gear, release the lock pin and set the camshaft timing gear to the advanced position before installation.


    1. A019NQZE04
      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 rotates to the retarded position, release the lock pin and set the camshaft timing gear to the advanced position.

    2. A019KVLE02
      Text in Illustration
      *1 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.

    3. A019KYDE10
      Text in Illustration
      *1 Camshaft Timing Gear
      *2 Clearance
      *3 Flange
      *a INCORRECT
      *b CORRECT
      *c No Clearance

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

    4. 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.

    5. A019OYGE04

      Release the lock pin.

      Text in Illustration
      *1 Rubber
      *2 Vinyl Tape
      *3 Knock Pin
      *a Retard Side Path
      *b Advance Side Path
      *c Open
      *d Close

      1. 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 three of the paths with pieces of rubber.

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

      4. A019NIW

        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).

        CAUTION:

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

        Note

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

    6. Remove the bolt and camshaft timing gear.

      Note

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

  2. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect the valve lash adjuster before installing it Click here.

    2. Install the 16 lash adjusters to the cylinder head.

      Note

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

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


    1. A019LK7E04
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Valve Lash Adjuster
      *3 Valve Stem Cap

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

    2. Install the 16 valve rocker arms as shown in the illustration.

  4. INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean the No. 2 camshaft bearing.

    2. Install the camshaft bearing to the camshaft housing.

    3. A019OHCE02
      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.)

  5. INSTALL NO. 1 CAMSHAFT BEARING


    1. A019MF0E02
      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.)

  6. INSTALL OIL CONTROL VALVE FILTER


    1. A019L6WE01

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

  7. INSTALL CAMSHAFT


    1. Clean the camshaft journals, camshaft housing and bearing caps.

    2. Apply a light coat of engine oil to the camshaft journal, camshaft housing and bearing caps.

    3. Install the No. 1 and No. 2 camshafts to the camshaft housing.

  8. INSTALL CAMSHAFT BEARING CAP


    1. A019P8TE01

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

    2. A019M63E02

      Install the 11 bolts in the order shown in the illustration.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

      Note

      Make sure that the camshaft rotates smoothly after installing the bearing caps.

  9. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A019P87E04
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Valve Stem Cap
      *3 Valve Lash Adjuster
      *a INCORRECT
      *b CORRECT

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

    2. A019LGJE01

      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.

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

    3. A019LBUE04
      Text in Illustration
      *1 Knock Pin
      *a Approximately 17°
      *b Approximately 2°

      Position the knock pin of the No. 1 and No. 2 camshafts as shown in the illustration.

    4. A019ORRE02

      Install the camshaft housing, and then install the 20 bolts in the order shown in the illustration.

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

      Note


      • Do not apply oil for at least 4 hours after installation.

      • Do not start the engine for at least 4 hours after installation.

      • Thoroughly wipe clean any seal packing.

  10. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. A019L3SE02
      Text in Illustration
      *1 Knock Pin Hole
      *2 Alignment Mark

      Check the camshaft timing gear position.

      If the camshaft timing gear is not set to the advanced position, release the lock pin and reset the camshaft timing gear (Refer to the "Set Camshaft Timing Gear Assembly" procedure).

    2. A019KVLE02
      Text in Illustration
      *1 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.

    3. A019KYDE10
      Text in Illustration
      *1 Camshaft Timing Gear
      *2 Clearance
      *3 Flange
      *a INCORRECT
      *b CORRECT
      *c No Clearance

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

    4. A019KLG

      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.

      • Do not disassemble the camshaft timing gear.

  11. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A019OQ7E02
      Text in Illustration
      *1 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.

    2. A019KYDE10
      Text in Illustration
      *1 Camshaft Timing Gear
      *2 Clearance
      *3 Flange
      *a INCORRECT
      *b CORRECT
      *c No Clearance

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

    3. A019KJS

      Using a wrench to hold the hexagonal portion of the No. 2 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.

      • Do not disassemble the camshaft timing exhaust gear.

  12. ADD ENGINE OIL


    1. A019MQF

      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.

  13. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A019L3WE02
      Text in Illustration
      *a 40°

      Temporarily install the crankshaft pulley bolt.

    2. Rotate the crankshaft 40° counterclockwise to position the crankshaft pulley key as shown in the illustration.

    3. A019O9RE03
      Text in Illustration
      *1 Timing Mark
      *a Approximately 7°
      *b Approximately 32°

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

      Tech Tips

      "A" is not a timing mark.

  14. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A019LB2

      Install the No.1 chain vibration damper with the 2 bolts.

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

  15. INSTALL CHAIN SUB-ASSEMBLY


    1. Place the chain onto the camshaft timing gears and crankshaft timing sprocket.

      Tech Tips


      • Make sure the mark plate of the chain faces away from the engine.

      • It is not necessary to install the chain to the teeth of the gears and sprocket.

    2. A019JY9E02
      Text in Illustration
      *1 Mark Plate
      *2 Timing Mark

      Align the mark plate (yellow or gold) of the chain with the timing mark of the camshaft timing exhaust gear and install the chain to the camshaft timing exhaust gear.

    3. A019KB7E02
      Text in Illustration
      *1 Mark Plate
      *2 Timing Mark

      Align the mark plate (pink or gold) of the chain with the timing mark of the crankshaft timing sprocket and install the chain to the crankshaft timing sprocket.

    4. A019KJE

      Tie a string above the crankshaft timing sprocket so that the chain is secure.

    5. A019L2RE03
      Text in Illustration
      *a Mark Plate
      *b Timing Mark

      Using the hexagonal portion of the intake camshaft, rotate the intake camshaft counterclockwise with a wrench, align the timing mark of the camshaft timing gear with the mark plate (yellow or gold) of the chain and install the chain to the camshaft timing gear.

      Tech Tips

      Hold the intake camshaft in place with a wrench until the chain tensioner is installed.

    6. A019LF0

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

      Note

      Make sure the chain is secure.

  16. INSTALL CHAIN TENSIONER SLIPPER


    1. A019KGH

      Install the chain tensioner slipper with the bolt.

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

  17. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A019LHS

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

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

    2. Remove the pin from the stopper plate.

  18. INSTALL TIMING CHAIN GUIDE


    1. A019KFN

      Install the timing chain guide with the bolt

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

  19. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

      A019OTDE04
      Text in Illustration
      *1 Timing Mark *2 Key
      *a Approximately 7° *b Approximately 32°

    2. Rotate the crankshaft clockwise, and check that the timing marks on the crankshaft timing sprocket and camshaft timing gears are as shown in the illustration.

      Tech Tips

      "A" is not a timing mark.

    3. Remove the crankshaft pulley bolt.

  20. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here