PROCEDURE
INSTALL VALVE LASH ADJUSTER ASSEMBLY
INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY
*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.
*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 | ||||||||
---|---|---|---|---|---|---|---|---|
|
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.
Set the camshaft and No. 2 camshaft as shown in the illustration.
Install the camshaft housing with the 17 bolts and tighten them in the order shown in the illustration.
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.
INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
*1 | Straight Pin |
*2 | Pin Hole |
Put the camshaft timing exhaust gear and camshaft together by aligning the pin hole and straight pin.
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.
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).
*1 | Camshaft Timing Gear |
*2 | Clearance |
*3 | Flange |
*4 | No Clearance |
Check that there is no clearance between the gear and camshaft flange.
Tighten the flange bolt with the camshaft timing exhaust gear secured in place.
Check the camshaft timing exhaust gear lock.
Make sure that the camshaft timing exhaust gear is locked.
INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
*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.
*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).
*1 | Camshaft Timing Gear |
*2 | Clearance |
*3 | Flange |
*4 | No Clearance |
Check that there is no clearance between the camshaft timing gear and camshaft flange.
Tighten the flange bolt with the camshaft timing gear secured in place.
*1 | Lock |
Check that the camshaft timing gear can move in the retard direction (clockwise) and is locked in the most retarded position.
INSTALL NO. 1 CHAIN VIBRATION DAMPER
Install the chain vibration damper with the 2 bolts.
SET NO. 1 CYLINDER TO TDC/COMPRESSION
*1 | Timing Gear Key |
Temporarily install the crankshaft pulley bolt.
Turn the crankshaft counterclockwise to position the timing gear key at the top.
*1 | Timing Mark |
Check that the timing marks on the camshaft timing gears are aligned as shown in the illustration.
Remove the crankshaft pulley bolt.
INSTALL CHAIN SUB-ASSEMBLY
Align the mark plate (orange) with the timing mark as shown in the illustration and install the chain.
*1 | Mark Plate (Orange) |
*2 | Timing Mark |
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.
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.
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.
*1 | Timing Mark |
*2 | Mark Plate (Yellow or Pink) |
Align the mark plate (yellow or pink) and timing mark and install the chain to the crankshaft timing gear.
Tech Tips
The mark plate on the crankshaft side is colored yellow or pink.
INSTALL CHAIN TENSIONER SLIPPER
Install the chain tensioner slipper to the cylinder block.
CHECK NO. 1 CYLINDER TO TDC/COMPRESSION
Check each timing mark at TDC/compression.
*1 | Timing Mark | *2 | Mark Plate (Orange) |
*3 | Mark Plate (Yellow or Pink) | - |
INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
INSTALL TIMING CHAIN COVER OIL SEAL
INSTALL CRANKSHAFT PULLEY
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
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.
Install a new gasket, the chain tensioner and bracket with the 2 nuts.
Note
If the hook releases the plunger while the chain tensioner is being installed, set the hook again.
*1 | Release |
*2 | Pin |
*3 | Hook |
*4 | Turn |
Rotate the crankshaft counterclockwise slightly and check that the hook becomes released.
*1 | Plunger |
*2 | Plunger Extended |
*3 | Turn |
Turn the crankshaft clockwise and check that the plunger is extended.
INSTALL SPARK PLUG TUBE GASKET
INSTALL CYLINDER HEAD COVER GASKET
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
INSTALL RADIO SETTING CONDENSER
INSTALL IGNITION COIL ASSEMBLY
INSTALL NO. 1 VACUUM PUMP BRACKET
INSTALL VACUUM PUMP ASSEMBLY
INSTALL THERMOSTAT
INSTALL WATER INLET
INSTALL WATER INLET HOSE
CONNECT NO. 3 WATER BY-PASS HOSE
INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
INSTALL FUEL INJECTOR ASSEMBLY
INSTALL NO. 1 DELIVERY PIPE SPACER
INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
INSTALL FUEL TUBE SUB-ASSEMBLY
INSTALL WIRE HARNESS CLAMP BRACKET
INSTALL AIR TUBE
INSTALL INTAKE MANIFOLD
INSTALL THROTTLE BODY ASSEMBLY
INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
Install the engine assembly with transaxle Click here.