CAMSHAFT INSTALLATION

PROCEDURE


  1. INSTALL NO. 1 CAMSHAFT BEARING


    1. Clean both surfaces of the bearings.

    2. Install the 2 No. 1 camshaft bearings.

    3. B005Y2OE01
      Text in Illustration
      *1 Vernier Caliper

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

      Standard dimension (A - B)
      0.7 mm (0.0276 in.) or less

      Note

      Position the bearings to the center of the bearing cap by measuring dimensions A and B.

  2. INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean both surfaces of the bearings.

    2. Install the 2 No. 2 camshaft bearings.

    3. B005YQ9E04
      Text in Illustration
      *1 Vernier Caliper

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

      Standard dimension (A)
      1.05 to 1.75 mm (0.0413 to 0.0689 in.)

      Note

      Position the bearings to the center of the bearing cap by measuring dimension A.

  3. INSTALL NO. 2 CAMSHAFT


    1. Clean the camshaft journals.

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

    3. Install the No. 2 camshaft to the camshaft housing.

  4. INSTALL CAMSHAFT


    1. Clean the camshaft journals.

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

    3. Install the camshaft to the camshaft housing.

  5. INSTALL BEARING CAP


    1. Apply engine oil to the camshaft journals, camshaft housings and bearing caps.

    2. B005Y1CE01
      Text in Illustration
      *1 Knock Pin
      *2 Camshaft

      Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.

    3. B005YS2E04

      Tighten the 10 bolts in the order shown in the illustration.

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

  6. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. B005ZCQE04
      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.

    2. B005XRPE11
      *1 7.0 mm
      *2 8.0 mm
      *3 3.5 to 4.5 mm

      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 of applying seal packing.

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

    3. B005Z7UN01

      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.

      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 is 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 is 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.

  7. INSTALL CAMSHAFT TIMING SPROCKET


    1. Tighten the flange bolt with the camshaft timing sprocket secured in place.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

  8. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. B005Z7YE16
      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. B005Z9NE02
      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. B005XZOE22
      Text in Illustration
      *1 Camshaft Timing Gear
      *2 Flange
      *a Clearance
      *b No Clearance

      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. B005Z4LE05
      Text in Illustration
      *a Lock

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

  9. 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 }

  10. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. B005Z79E04
      Text in Illustration
      *1 Timing Gear Key

      Temporarily install the crankshaft pulley bolt.

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

    3. B005ZV6E01
      Text in Illustration
      *1 Timing Mark (Rectangle)
      *2 Timing Mark
      *3 Mark (Circle)

      Check that the timing marks on the camshaft timing gear and camshaft timing sprocket are aligned as shown in the illustration.

      Note

      There are 3 marks on the camshaft timing sprocket. Make sure that the timing mark (rectangle) is at the top.

    4. Remove the crankshaft pulley bolt.

  11. INSTALL CHAIN SUB-ASSEMBLY


    1. B005XX6E01
      Text in Illustration
      *1 Mark Plate (Orange)
      *2 Timing Mark (Rectangle)
      *3 Mark (Circle)
      *a Place the Chain on the Sprocket
      *b Pass the Chain through the Damper

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

      Note

      There are 3 marks on the camshaft timing sprocket. Make sure to align the mark plate with the timing mark (rectangle).

      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. B005XI9

      Place the chain on the crankshaft without passing it around the shaft.

    3. 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.

      B005ZSCE01
      Text in Illustration
      *1 Mark Plate (Orange)
      *2 Timing Mark
      *a Tension the Chain

    4. 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.

    5. B005XHXE13
      Text in Illustration
      *1 Mark Plate (Pink)
      *2 Timing Mark

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

  12. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Check each timing mark at TDC/compression.

      B005YVTE04
      Text in Illustration
      *1 Timing Mark *2 Mark Plate (Orange)
      *3 Mark Plate (Pink) *4 Timing Mark (Rectangle)
      *5 Mark (Circle) - -

      Note

      There are 3 marks on the camshaft timing sprocket. Make sure that the timing mark (rectangle) is at the top.

  13. INSTALL NO. 2 CHAIN VIBRATION DAMPER


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

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

  14. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper to the cylinder block.

  15. INSTALL TIMING CHAIN COVER OIL SEAL

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  16. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

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  17. INSTALL CRANKSHAFT PULLEY

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  18. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B005XVHE02
      Text in Illustration
      *1 Cam
      *2 Pin
      *3 Hook
      *a Push
      *b Raise
      *c CORRECT
      *d INCORRECT

      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. B005XT3

      Install a new gasket, the bracket and chain tensioner 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.

    3. B005Y5RE04
      Text in Illustration
      *1 Pin
      *2 Hook
      *a Push
      *b Turn
      *c Disconnect

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

    4. B005YVPE04
      Text in Illustration
      *1 Plunger
      *a Turn
      *b Plunger Extended

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

  19. INSTALL SPARK PLUG TUBE GASKET

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  20. INSTALL CYLINDER HEAD COVER GASKET

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  21. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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  22. INSTALL IGNITION COIL ASSEMBLY

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  23. INSTALL FUEL INJECTOR ASSEMBLY

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  24. INSTALL NO. 1 DELIVERY PIPE SPACER

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  25. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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  26. INSTALL FUEL VAPOR FEED PIPE

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  27. INSTALL INTAKE MANIFOLD

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  28. INSTALL EGR VALVE WITH COOLER ASSEMBLY

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  29. REMOVE EGR PIPE ASSEMBLY

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  30. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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  31. INSTALL THROTTLE BODY ASSEMBLY

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  32. INSTALL ENGINE HANGER

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  33. REMOVE ENGINE STAND

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  34. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

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