Engine Mechanical (3MZ-FE): Camshaft: Installation

INSTALL CAMSHAFT SUB GEAR
1. Clamp the camshaft in a vise on the hexagonal lobe.
  NOTE: Be careful not to damage the camshaft.
  
  Fig 1: Clamping Camshaft In Vise On Hexagonal Lobe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the camshaft gear bolt washer and the camshaft sub-gear.
  HINT:
  
  Attach the pins on the gears to the gear bolt washer ends.
3. Install the wave washer.
  
  Fig 2: Installing Camshaft Gear Bolt Washer And Camshaft Sub-Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using snap ring pliers, install the snap ring.
  
  Fig 3: Removing/Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST, align the holes of the camshaft main gear and sub-gear by turning camshaft sub-gear counterclockwise, and temporarily install a service bolt.
  SST 09960-10010 (09962-01000, 09963-00500)
  
  Fig 4: Installing Service Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Align the gear teeth of the main gear and sub-gear, and tighten the service bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

NOTE: Be careful not to damage the camshaft journals.

HINT:

NOTE: When installing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by installation of the service bolt.
INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
1. Align the alignment pin with the groove and install the VVT-i on the camshaft.
  NOTE: Install it with the lock-pin engaged and locked at the most retard angle position.
2. Apply engine oil to the nut, the mounting surface of VVT-i and the screw threads.
  NOTE:
  - Be sure to apply the oil, otherwise the specified torque cannot be obtained.
  - New nut must be used when replacing the VVT-i unit.
  Fig 5: Aligning Alignment Pin With Groove
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a 46 mm socket wrench, install and tighten a lock nut by turning it counterclockwise.
Torque: 150 N*m (1,530 kgf*cm, 111 ft.*lbf)
NOTE:
- The lock nut has LH threads.
- Never use any tool other than the socket wrench. Other tools will deform the cam angle rotor.
Fig 6: Tightening Lock Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.
1. Apply new engine oil to the thrust portion and journal of the camshaft.
2. Place the No. 4 camshaft at 90° angle of the timing mark (1-dot marks) on the cylinder head.
3. Apply MP grease to a new oil seal lip.
  
  Fig 7: Placing No 4 Camshaft At 90° Angle Of Timing Mark (1-Dot Marks) On Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the oil seal to the camshaft.
  NOTE:
  - Do not turn over the oil seal lip.
  - Insert the oil seal until it stops.
5. Remove any old packing material from the contact surface.
  
  Fig 8: Installing Oil Seal To Camshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Apply seal packing to the No. 1 bearing cap as shown in the illustration.
  Seal packing:
  
  Part No. 08826-00080 or equivalent
  NOTE:
  - Install the No. 1 bearing cap within 5 minutes after applying seal packing.
  - Do not expose the seal to engine oil within 2 hours after installing.
  Fig 9: Locating Seal Packing On No 1 Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install the 5 bearing caps in their proper locations.
8. Apply a light coat of engine oil on the threads of the bearing cap bolts.
  
  Fig 10: Installing Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Using several steps, install and tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.

Fig 11: Identifying Bearing Cap Bolts Tightening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Apply new engine oil to the thrust portion and journal of the camshaft.
2. Align the timing marks (1 dot mark) of the camshaft drive gear with the mark on the driven gears.
3. Place the camshaft on the cylinder head.
  
  Fig 12: Aligning Timing Marks (1 Dot Mark) Of Camshaft Drive Gear With Mark On Driven Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 5 bearing caps in their proper locations.
5. Apply a light coat of engine oil to the threads of the bearing cap bolts.
  
  Fig 13: Installing Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using several steps, install and tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
  Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
7. Remove the service bolt.
Fig 14: Identifying Bearing Cap Bolts Tightening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 CAMSHAFT
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.
1. Apply new engine oil to the thrust portion and journal of the camshaft.
2. Place the No. 2 camshaft at 90° angle of the timing mark (2 dot marks) on the cylinder head.
3. Apply MP grease to a new oil seal lip.
  
  Fig 15: Placing No 2 Camshaft At 90° Angle Of Timing Mark (2 Dot Marks) On Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the oil seal to the camshaft.
  NOTE:
  - Do not turn over the oil seal lip.
  - Insert the oil seal until it stops.
5. Remove any old packing material from the contact surface.
  
  Fig 16: Installing Oil Seal To Camshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Apply seal packing to the No. 1 bearing cap as shown in the illustration.
  Seal Packing :
  
  Part No.08826-00080 or equivalent
  NOTE:
  - Install the No. 1 bearing cap within 5 minutes after applying seal packing.
  - Do not expose the seal to engine oil within 2 hours after installing.
  Fig 17: Locating Seal Packing On No 1 Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install the 5 bearing caps in their proper locations.
8. Apply a light coat of engine oil on the threads of the bearing cap bolts.
  
  Fig 18: Installing Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)

Fig 19: Identifying Bearing Cap Bolts Tightening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.
1. Apply new engine oil to the thrust portion and journal of the camshaft.
2. Align the timing marks (2 dot marks) of the camshaft drive gear with the mark on the driven gears.
3. Place the camshaft on the cylinder head.
  
  Fig 20: Aligning Timing Marks (2 Dot Marks) Of Camshaft Drive Gear With Mark On Driven Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 5 bearing caps in their proper locations.
5. Apply a light coat of engine oil to the threads of the bearing cap bolts.
  
  Fig 21: Installing Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
  Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
7. Remove the service bolt.

INSTALL TIMING BELT NO. 3 COVER

Visually check for cracks and breaks on the gasket of the timing belt cover.
HINT:

If there is a trace of water is found in the visual check, repair it with seal packing when the crack length is within 2 to 3 cm (0.79 to 1.18 in.). Replace the gasket when the crack length is 3 to 4 cm (1.18 to 1.57 in.) and more.

Fig 22: Identifying Bearing Cap Bolts Tightening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
If the timing belt cover gasket is needed to repair, follow the procedure below.
1. Repair the cracks and breaks by applying the seal packing to the damaged area.
Seal packing:

Part No.08826-00080 or equivalent

NOTE: When applying the seal packing, apply it as wide and high as possible to fill the surface area of the gasket.

Fig 23: Applying Seal Packing To Damaged Area
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the timing belt cover gasket is needed to replace, follow the procedure below.

Using a screwdriver and gasket scraper, remove the remaining gasket.
NOTE: Be careful not to damage the timing belt cover.

Remove the backing paper from a new gasket, and affix the gasket along the groove of the timing belt cover as shown in the illustration.

NOTE:

Affix the gasket in the center of the groove.
At the corners, try to keep the gasket thickness uniform.

HINT:

Gasket length

Fig 24: Affixing Gasket Along Groove Of Timing Belt Cover

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

GASKET LENGTH SPECIFICATION

Gasket	D	E	F	G
Length	335 mm (13.19 in.)	180 mm (7.09 in.)	133 mm (5.24 in.)	72 mm (2.83 in.)

If there is a gap on the joint of the gasket, apply seal packing to close the gap.

Seal packing:

Part No.08826-00080 or equivalent

NOTE: When applying the seal packing, apply it as wide and high as the gasket.

Install the timing belt cover with the 6 bolts.

Torque: 8.5 N*m (87 kgf*cm, 76 in.*lbf)

INSTALL CAMSHAFT TIMING PULLEY
1. Paying attention to the orientation of the belt guide, install the camshaft timing pulley with the belt guide properly oriented and tighten the bolt temporally.
  
  Fig 25: Identifying Camshaft Timing Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  - Face the belt guide of the RH timing pulley toward front of the engine.
  - Face the belt guide of the LH timing pulley toward rear of the engine.
2. Using SST, tighten the RH pulley bolt.
  SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
  
  Torque: 125 N*m (1,275 kgf*cm, 92 ft.*lbf)
  
  NOTE: The torque indicated above is for used without SST on extension tool. If you are using extension tools, find the reading of the torque wrench by the formula (See REPAIR INSTRUCTION ).
  
  Extended length:
  
  SST (09249-63010) 150 mm (5.91 in.)
3. Using SST, tighten the LH pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)

Torque: 125 N*m (1,275 kgf*cm, 92 ft.*lbf)

Fig 26: Tightening RH Pulley Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO. 2
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
INSPECT TIMING BELT
Inspect the timing belt (See INSPECTION ).

Fig 27: Tightening LH Pulley Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TIMING BELT
SST 09960-10010 (09962-01000, 09963-01000)
1. Install the timing belt (See INSTALLATION ).
INSTALL CHAIN TENSIONER ASSEMBLY NO. 1
1. Install the chain tensioner assembly No. 1 (See INSTALLATION ).
INSTALL TIMING BELT GUIDE NO. 2
1. Install the timing belt guide No. 2 (See INSTALLATION ).
INSTALL ENGINE MOUNTING BRACKET RH
1. Install the engine mounting bracket RH (See INSTALLATION ).
INSTALL TIMING BELT NO. 2 COVER
1. Install the timing belt No. 2 cover (See INSTALLATION ).
INSTALL TIMING BELT NO. 1 COVER
1. Install the timing belt No. 1 cover (See INSTALLATION ).
INSTALL CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021
1. Install the crankshaft pulley (See INSTALLATION ).
INSTALL GENERATOR BRACKET NO. 2
1. Install the generator bracket No. 2 (See INSTALLATION ).
INSTALL ENGINE MOUNTING STAY NO. 2 RH
1. Install the engine mounting stay No. 2 RH (See INSTALLATION ).
INSTALL ENGINE MOVING CONTROL ROD
1. Install the engine moving control rod (See INSTALLATION ).
INSPECT VALVE CLEARANCE
1. Inspect the valve clearance (See ADJUSTMENT ).
ADJUST VALVE CLEARANCE
SST 09248-55040 (09248-05410, 09248-05420)
1. Adjust valve clearance (See ADJUSTMENT ).
INSTALL VANE PUMP V-BELT
1. Install the vane pump V-belt (See INSTALLATION ).
INSTALL V-(COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1
1. Install the V-(cooler compressor to crankshaft pulley) belt No. 1 (See INSTALLATION ).
INSPECT DRIVE BELT DEFLECTION AND TENSION
1. Inspect the drive belt deflection and tension (reference) (See DRIVE BELT ).
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
1. Install the cylinder head cover sub-assembly LH (See ADJUSTMENT ).
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
1. Install the cylinder head cover sub-assembly (See ADJUSTMENT ).
INSTALL IGNITION COIL ASSEMBLY
Torque: 8.0 N*m (80 kgf*cm, 71 in.*lbf)
1. Install the ignition coil assembly (See ADJUSTMENT ).
INSTALL INTAKE AIR SURGE TANK
1. Install the intake air surge tank (See ADJUSTMENT ).
INSTALL EMISSION CONTROL VALVE SET
1. Install the emission control valve set (See ADJUSTMENT ).
INSTALL AIR CLEANER CAP SUB-ASSEMBLY
1. Install the air cleaner cap sub-assembly (See INSTALLATION ).
CONNECT VACUUM HOSE
1. Connect the vacuum hose (See INSTALLATION ).
INSTALL V-BANK COVER SUB-ASSEMBLY
1. Install the V-bank cover sub-assembly (See ADJUSTMENT ).
INSTALL RADIATOR HOSE INLET
INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER
1. Install the cowl top panel sub-assembly outer (See INSTALLATION ).
INSTALL WINDSHIELD WIPER LINK ASSEMBLY
1. Install the windshield wiper link assembly (See INSTALLATION ).
INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY
1. Install the cowl top ventilator louver sub-assembly (See INSTALLATION ).
INSTALL FR WIPER ARM LH
1. Install the FR wiper arm LH (See INSTALLATION ).
INSTALL FR WIPER ARM RH
1. Install the FR wiper arm RH (See INSTALLATION ).
INSTALL FRONT WHEEL RH
1. Install the front wheel RH (See INSTALLATION ).
ADD ENGINE COOLANT
1. Add engine coolant (See COOLANT ).
CHECK FOR ENGINE COOLANT LEAKAGE
1. Check for engine coolant leakage (See COOLING SYSTEM ).