CAMSHAFT INSTALLATION

CAUTION / NOTICE / HINT

Tip:

Perform "Inspection After Repairs" after replacing the camshaft housing sub-assembly, camshaft timing gear assembly or camshaft timing exhaust gear assembly (Click here).

PROCEDURE

  1. INSTALL VALVE LASH ADJUSTER ASSEMBLY

    Click here

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

    Click here

  3. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

    Tip:

    Perform "Inspection After Repairs" after replacing the camshaft housing sub-assembly (Click here).

    1. A153836E01

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

      Table 1. Text in Illustration

      *1

      Valve Stem Cap

      *2

      Valve Rocker Arm

      *3

      Valve Lash Adjuster
    2. A206178E09

      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

      Item

      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.

    3. U121325E02

      Set the camshaft and No. 2 camshaft as shown in the illustration.

    4. Install the camshaft housing with the 17 bolts and tighten them in the order shown in the illustration.

      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.

  4. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Tip:

    Perform "Inspection After Repairs" after replacing the camshaft timing exhaust gear assembly (Click here).

    1. A390258E01

      Put the camshaft timing exhaust gear and camshaft together by aligning the pin hole and straight pin.

      Table 2. Text in Illustration

      *1

      Straight Pin

      *2

      Pin Hole
      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. A146267E01

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

    4. A165297

      Tighten the flange bolt with the camshaft timing exhaust gear secured in place.

      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.

  5. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    Tip:

    Perform "Inspection After Repairs" after replacing the camshaft timing gear assembly (Click here).

    1. A146265E02

      Put the camshaft timing gear and camshaft together with the straight pin and key groove misaligned as shown in the illustration.

      Table 3. Text in Illustration

      *1

      Straight Pin

      *2

      Key Groove
      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. A389838E01

      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.

      Table 4. Text in Illustration

      *1

      Straight Pin

      *2

      Key Groove
      Note:

      Do not turn the camshaft timing gear in the retard direction (clockwise).

    3. A146267E01

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

    4. A165296

      Tighten the flange bolt with the camshaft timing gear secured in place.

      54 N*m

      551 kgf*cm

      40 ft.*lbf

    5. U121311E01

      Check that the camshaft timing gear can move in the retard direction (clockwise) and is locked in the most retarded position.

      Table 5. Text in Illustration

      *1

      Lock

  6. INSTALL NO. 1 CHAIN VIBRATION DAMPER

    1. A173475

      Install the chain vibration damper with the 2 bolts.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

  7. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    1. A153029E02

      Temporarily install the crankshaft pulley bolt.

    2. Turn the crankshaft counterclockwise to position the timing gear key at the top.

      Table 6. Text in Illustration

      *1

      Timing Gear Key
    3. A153030E09

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

      Table 7. Text in Illustration

      *1

      Timing Mark

    4. Remove the crankshaft pulley bolt.

  8. INSTALL CHAIN SUB-ASSEMBLY

    1. Align the mark plate (orange) with the timing mark as shown in the illustration and install the chain.

      A389839E01
      Table 8. Text in Illustration

      *1

      Mark Plate (Orange)

      *2

      Timing Mark
      Tip:

      • 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.

      Tip:

      To tension the chain, slowly turn the camshaft timing gear clockwise to prevent the chain from being misaligned.

    4. A150939E12

      Align the mark plate (yellow or pink) and timing mark and install the chain to the crankshaft timing gear.

      Table 9. Text in Illustration

      *1

      Timing Mark

      *2

      Mark Plate (Yellow or Pink)
      Tip:

      The mark plate on the crankshaft side is colored yellow or pink.

  9. INSTALL CHAIN TENSIONER SLIPPER

    1. A173477

      Install the chain tensioner slipper to the cylinder block.

  10. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

    1. Check each timing mark at TDC/compression.

      U121796E01
      Table 10. Text in Illustration

      *1

      Timing Mark

      *2

      Mark Plate (Orange)

      *3

      Mark Plate (Yellow or Pink)

      -

      -

  11. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  12. INSTALL TIMING CHAIN COVER OIL SEAL

    Click here

  13. INSTALL CRANKSHAFT PULLEY

    Click here

  14. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    1. A162975E01

      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.

    2. A150932

      Install a new gasket, the chain tensioner and bracket with the 2 nuts.

      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.

    3. A165312E01

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

      Table 11. Text in Illustration

      *1

      Release

      *2

      Pin

      *3

      Hook

      *4

      Turn
    4. A165313E01

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

      Table 12. Text in Illustration

      *1

      Plunger

      *2

      Plunger Extended

      *3

      Turn

  15. INSTALL SPARK PLUG TUBE GASKET

    Click here

  16. INSTALL CYLINDER HEAD COVER GASKET

    Click here

  17. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  18. INSTALL IGNITION COIL ASSEMBLY

    Click here

  19. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

    Click here

  20. INSTALL NO. 1 VACUUM PUMP BRACKET

    Click here

  21. INSTALL VACUUM PUMP ASSEMBLY

    Click here

  22. INSTALL THERMOSTAT

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  23. INSTALL WATER INLET

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  24. INSTALL WATER INLET HOSE

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  25. CONNECT NO. 3 WATER BY-PASS HOSE

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  26. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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  27. INSTALL FUEL INJECTOR ASSEMBLY

    Click here

  28. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

    Click here

  29. INSTALL FUEL TUBE SUB-ASSEMBLY

    Click here

  30. INSTALL WIRE HARNESS CLAMP BRACKET

    Click here

  31. INSTALL AIR TUBE

    Click here

  32. INSTALL INTAKE MANIFOLD

    Click hereClick here

  33. INSTALL THROTTLE BODY ASSEMBLY

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  34. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    1. Install the engine assembly with transaxle (Click here).