CAMSHAFT INSTALLATION

CAUTION / NOTICE / HINT

Tip:

Perform "Inspection After Repair" after replacing the camshaft housing sub-assembly, camshaft timing gear assembly or camshaft timing exhaust gear assembly.

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PROCEDURE

  1. INSTALL VALVE LASH ADJUSTER ASSEMBLY

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

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  3. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

    1. A294385C01

      *1

      No. 1 Valve Rocker Arm Sub-assembly

      *2

      Valve Stem Cap

      *3

      Valve Lash Adjuster Assembly

      *a

      Correct

      *b

      Incorrect

      Check that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.

    2. A206178N02

      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 sub-assembly 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. A289825N02

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

    4. Install the camshaft housing sub-assembly 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 sub-assembly, 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 sub-assembly, clean the installation surfaces, and reapply seal packing.

      • If the camshaft housing sub-assembly 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 sub-assembly, wipe off any seal packing that seeped out from between the camshaft housing sub-assembly and cylinder head sub-assembly.

      Tip:

      Perform "Inspection After Repair" after replacing the camshaft housing sub-assembly.

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  4. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    1. A215318C04

      *1

      Straight Pin

      *a

      Pin Hole

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

      Note:

      Do not forcibly push in the camshaft timing exhaust gear assembly. This may cause the camshaft straight pin tip to damage the installation surface of the camshaft timing exhaust gear assembly.

    2. Lightly press the camshaft timing exhaust gear assembly against the camshaft and turn the camshaft timing exhaust gear assembly. Push further at the position where the pin enters the hole.

      Note:

      Be sure not to turn the camshaft timing exhaust gear assembly in the retard direction (clockwise).

    3. A146267C10

      *1

      Camshaft Timing Exhaust Gear Assembly

      *a

      Flange

      *b

      Clearance

      *c

      No Clearance

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

    4. A165297

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

      54 N*m

      551 kgf*cm

      40 ft.*lbf

    5. Check the camshaft timing exhaust gear assembly lock.

      1. Make sure that the camshaft timing exhaust gear assembly is locked.

        Tip:

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

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  5. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    1. A146265C07

      *1

      Straight Pin

      *a

      Key Groove

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

      Note:

      Do not forcibly push in the camshaft timing gear assembly. This may cause the camshaft straight pin tip to damage the installation surface of the camshaft timing gear assembly.

    2. A215319C05

      *1

      Straight Pin

      *a

      Key Groove

      Turn the camshaft timing gear assembly 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 assembly in the retard direction (clockwise).

    3. A146267C13

      *1

      Camshaft Timing Gear Assembly

      *a

      Flange

      *b

      Clearance

      *c

      No Clearance

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

    4. A165296

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

      54 N*m

      551 kgf*cm

      40 ft.*lbf

    5. A165299C03

      *a

      Lock

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

      Tip:

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

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  6. INSTALL NO. 1 CHAIN VIBRATION DAMPER

    1. A173475

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

      21 N*m

      214 kgf*cm

      15 ft.*lbf

  7. SET NO. 1 CYLINDER TDC/COMPRESSION

    1. A153029C03

      *1

      Timing Gear Key

      Temporarily install the crankshaft pulley bolt.

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

    3. A282746C09

      *a

      Timing Mark

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

    4. Remove the crankshaft pulley bolt.

  8. INSTALL CHAIN SUB-ASSEMBLY

    1. Align the mark plates (orange) with the timing marks as shown in the illustration and install the chain sub-assembly.

      A282747C04

      *a

      Mark Plate (Orange)

      *b

      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 sub-assembly around the sprocket of the camshaft timing gear assembly. Only place it on the sprocket.

      • Pass the chain sub-assembly through the No. 1 chain vibration damper.

    2. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly counterclockwise to align the mark plate (orange) and timing mark, and then install the chain sub-assembly.

    3. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly clockwise.

      Tip:

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

    4. A150939C08

      *a

      Mark Plate (Yellow or Pink)

      *b

      Timing Mark

      Align the mark plate (yellow or pink) and timing mark and install the chain sub-assembly to the crankshaft timing sprocket.

      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 sub-assembly.

  10. CHECK NO. 1 CYLINDER TDC/COMPRESSION

    1. Check each timing mark at TDC/compression.

      A282748C04

      *a

      Timing Mark

      *b

      Mark Plate (Orange)

      *c

      Mark Plate (Yellow or Pink)

      -

      -

  11. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

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  12. INSTALL TIMING CHAIN COVER OIL SEAL

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  13. INSTALL CRANKSHAFT PULLEY

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  14. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    1. A162975C03

      *a

      Cam

      *b

      Hook

      *c

      Plunger

      *d

      Pin

      *e

      Correct

      *f

      Incorrect

      *g

      Push

      *h

      Raise

      Release the cam, 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. A296127

      Install a new gasket, the bracket and No. 1 chain tensioner assembly with the 2 nuts.

      12 N*m

      122 kgf*cm

      9 ft.*lbf

      Note:

      If the hook releases the plunger while the No. 1 chain tensioner assembly is being installed, set the hook again.

    3. A282750C02

      *a

      Hook

      *b

      Disconnect

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

    4. A282751C02

      *a

      Plunger

      *b

      Plunger Extended

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

  15. INSTALL SPARK PLUG TUBE GASKET

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  16. INSTALL CYLINDER HEAD COVER GASKET

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  17. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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  18. INSTALL IGNITION COIL ASSEMBLY

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  19. INSTALL NO. 1 VACUUM PUMP BRACKET

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  20. INSTALL VACUUM PUMP ASSEMBLY

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  21. INSTALL WATER INLET HOSE

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  22. CONNECT NO. 3 WATER BY-PASS HOSE

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  23. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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  24. INSTALL WIRE HARNESS CLAMP BRACKET

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  25. INSTALL DUTY VACUUM SWITCHING VALVE

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  26. INSTALL INTAKE MANIFOLD

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  27. INSTALL THROTTLE BODY ASSEMBLY

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  28. INSTALL ENGINE HANGER

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  29. REMOVE ENGINE STAND

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