CAMSHAFT INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repair" after replacing the camshaft, No. 2 camshaft, camshaft timing gear assembly or camshaft timing exhaust gear assembly.

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PROCEDURE


  1. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

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  2. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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  3. INSTALL VALVE LASH ADJUSTER ASSEMBLY

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

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  5. 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. A01OAZTC06
      *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.

      Distance (A)
      1.15 to 1.85 mm (0.0453 to 0.0728 in.)

  6. INSTALL NO. 2 CAMSHAFT

    Tech Tips

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

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

  7. INSTALL CAMSHAFT

    Tech Tips

    Perform "Inspection After Repair" after replacing the camshaft.

    Click here


    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. Install the camshaft to the camshaft housing sub-assembly.

  8. 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. A01OBDIC06
      *1 No. 1 Camshaft Bearing
      *a No. 1 Camshaft Bearing Cap
      *b Vernier Caliper

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

      Difference between (A) and (B)
      0 to 0.7 mm (0 to 0.0276 in.)

  9. INSTALL OIL CONTROL VALVE FILTER


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

    2. 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.

  10. INSTALL CAMSHAFT BEARING CAP


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

    2. Apply a light coat of engine oil to the camshaft journals, No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap.

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

    4. A01OCR1C08
      *a No. 1 Camshaft Bearing Cap
      *b No. 2 Camshaft Bearing Cap
      *c No. 3 Camshaft Bearing Cap
      *d No. 4 Camshaft Bearing Cap

      Uniformly tighten the 11 bolts in several steps in the order 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.

  11. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A01OB7EC02
      *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 Packing Diameter
      3.0 to 4.0 mm (0.118 to 0.157 in.)

      Note


      • Remove any oil from the contact surface.

      • Check and clean the bolts and bolt holes.

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

      • Do not add engine oil for at least 2 hours after installation.

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

    2. A01OBGCC16
      *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. A01OC38C29
      *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. A01OB8GC01
      B008GAS Bolt (A)
      B008GGT Bolt (B)

      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 }

      Note

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

      Bolt Length
      Item Length
      Bolt (A) 70 mm (2.76 in.)
      Bolt (B) 45 mm (1.77 in.)

  12. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    Tech Tips

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

    Click here


    1. A01OB2PC05
      *a Lock Pin Released
      *b Pin Hole
      *c 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. A01O9A9C60
      *a Pin Hole
      *b Knock Pin

      Align and fit the knock pin of the camshaft to the pin hole of the camshaft timing gear assembly.

    3. A01O9C5C95
      *1 Camshaft Timing Gear Assembly
      *a Incorrect
      *b Correct
      *c Gap
      *d Camshaft Flange
      *e No Gap

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

    4. A01O9U6C02
      *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 cylinder head 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.

  13. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Tech Tips

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

    Click here


    1. A01O9A9C69
      *a Pin Hole
      *b Knock Pin

      Align and fit the knock pin of the No. 2 camshaft to the pin hole of the camshaft timing exhaust gear assembly.

    2. A01O9C5C95
      *1 Camshaft Timing Exhaust Gear Assembly
      *a Incorrect
      *b Correct
      *c Gap
      *d Camshaft Flange
      *e No Gap

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

    3. A01O9LHC01
      *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 cylinder head sub-assembly or spark plug tube with the wrench.

  14. ADD ENGINE OIL

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  15. INSTALL NO. 1 CHAIN VIBRATION DAMPER

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  16. INSTALL CHAIN SUB-ASSEMBLY

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  17. INSTALL CHAIN TENSIONER SLIPPER

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  18. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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  19. INSTALL TIMING CHAIN GUIDE

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  20. SET NO. 1 CYLINDER TO TDC / COMPRESSION

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  21. INSTALL TIMING CHAIN COVER ASSEMBLY

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