CAMSHAFT > INSTALLATION

for Preparation Click here



1. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    A098365E02
  1. Put the camshaft timing gear and camshaft together with the straight pin and key groove misaligned, as shown in the illustration.

  1. 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.

    NOTICE:
    Be sure not to turn the camshaft timing gear to the retard angle side (the right angle).
  1. Check that there is no clearance between the gear and camshaft.

  1. Tighten the flange bolt with the camshaft timing gear fixed in place.

    Torque:
    54 N*m{ 551 kgf*cm , 40 ft.*lbf }
  1. Check that the camshaft timing gear can move to the retard angle side (the right direction) and is locked in the most retarded position.



2. INSTALL CAMSHAFT
  1. Apply a light coat of engine oil to the journal portion of the camshaft.



    A098176E03
  1. Install the timing chain onto the camshaft timing gear with the paint mark aligned with the timing mark in the camshaft timing gear as shown in the illustration.



    A098177E03
  1. Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps into the cylinder head.

  1. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.



    A098177E06
  1. Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.

    Torque:
    No. 1 Bearing cap:
    30 N*m{ 301 kgf*cm , 22 ft.*lbf }
    No. 3 Bearing cap:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }


3. INSTALL NO. 2 CAMSHAFT
  1. Apply a light coat of engine oil to the journal portion of the No. 2 camshaft.



    A098178E03
  1. Put the No. 2 camshaft on the cylinder head with the paint mark of the chain aligned with the timing mark on the camshaft timing sprocket.



    A086659
  1. While holding the No. 2 camshaft by hand, temporarily tighten the camshaft timing sprocket set bolt.



    A098174E05
  1. Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head.

  1. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.



    A098174E07
  1. Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.

    Torque:
    No. 2 Bearing cap:
    30 N*m{ 301 kgf*cm , 22 ft.*lbf }
    No. 3 Bearing cap:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }


    A098173E04
  1. While holding the camshaft with a wrench, tighten the camshaft timing sprocket set bolt.

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


    A052460E05
  1. Check that the paint marks on the chain are aligned with the timing marks on the camshaft timing gear and camshaft timing sprocket. Also, check that the crankshaft pulley groove is aligned with the timing mark "0" of the timing chain cover.



4. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    A098376E03
  1. Release the ratchet pawl, then fully push in the plunger and hook the hook to the pin so that the plunger is in the position shown in the illustration.



    A098377E03
  1. Install a new gasket and the chain tensioner with the 2 nuts.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

    NOTICE:
    If the hook releases the plunger while the chain tensioner is being installed, set the hook again.


    A112204E02
  1. Turn the crankshaft counterclockwise, then disconnect the plunger knock pin from the hook.



    A112205E02
  1. Turn the crankshaft clockwise, then check that the plunger is extended.



5. CHECK VALVE CLEARANCE


    A098170E04
  1. Check only the valves indicated.

    1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

      Standard valve clearance (cold):
      Item
      Standard Condition
      Intake
      0.19 to 0.29 mm (0.0075 to 0.0114 in.)
      Exhaust
      0.38 to 0.48 mm (0.0150 to 0.0189 in.)
    2. Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve clearance lifters.

  1. Turn the crankshaft 1 revolution (360°) and set the No. 4 cylinder to the TDC/compression.



    A098171E04
  1. Check only the valves indicated.

    1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

      Standard valve clearance (cold):
      Item
      Standard Condition
      Intake
      0.19 to 0.29 mm (0.0075 to 0.0114 in.)
      Exhaust
      0.38 to 0.48 mm (0.0150 to 0.0189 in.)
    2. Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifters.



6. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
  1. Remove any old packing material from the contact surface.



    A094205E01
  1. Apply seal packing to the 2 locations shown in the illustration.

    Seal packing:
    Toyota Genuine Seal Packing Block, Three Bond 1207B or Equivalent

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Install the cylinder head cover within 3 minutes of applying seal packing.
    3. Do not add engine oil for at least 2 hours after installing the cylinder head cover.


    A127550E01
  1. Install the cylinder head cover with the 8 bolts and 2 nuts.

    Torque:
    Bolt A:
    11 N*m{ 112 kgf*cm , 8 ft.*lbf }
    Bolt B:
    14 N*m{ 143 kgf*cm , 10 ft.*lbf }
    Nut:
    11 N*m{ 112 kgf*cm , 8 ft.*lbf }


    A112210
  1. Install the 2 engine wires with the 2 bolts.

    Torque:
    8.4 N*m{ 86 kgf*cm , 74 in.*lbf }


7. INSTALL IGNITION COIL ASSEMBLY
  1. Install the 4 ignition coils with the 4 bolts.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }


8. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY


    A134904
  1. Install the engine cover with the 2 nuts.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }


9. INSTALL FRONT FENDER APRON SEAL RH


10. INSTALL ENGINE UNDER COVER LH


11. INSTALL ENGINE UNDER COVER RH


12. INSTALL FRONT WHEEL RH


13. CHECK FOR ENGINE OIL LEAKS