Installation

3UR-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION

1. INSTALL CAMSHAFT BEARING CAP RH
(a) Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.
(b) Install the No. 1 and No. 2 camshafts to the camshaft housing.

(d) Temporarily install the 10 bolts in the order shown in the illustration.
2. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

(a) Make sure that the valve rocker arms are installed as shown in the illustration.

(b) 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:
3.5 to 4.0 mm (0.138 to 0.157 in.)
NOTICE:

- Remove any oil from the contact surface.
- Install the camshaft housing within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

(c) Install the camshaft housing, and install the 18 bolts in the order shown in the illustration.
for bolt A - Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
except bolt A - Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
NOTICE:

- Do not start the engine for at least 2 hours after the installation.
- Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing.

(d) Tighten the 10 bolts in the order shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)
NOTICE:
Thoroughly wipe clean any seal packing.

3. INSTALL CAMSHAFT BEARING CAP LH
(a) Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.
(b) Install the No. 3 and No. 4 camshafts to the camshaft housing.

(d) Temporarily install the 10 bolts in the order shown in the illustration.
4. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH

(a) Make sure that the valve rocker arms are installed as shown in the illustration.

(d) Tighten the 10 bolts in the order shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)
NOTICE:
Thoroughly wipe clean any seal packing.

5. INSTALL CRANKSHAFT TIMING GEAR KEY [1][2]Reassembly

6. SET NO. 1 CYLINDER TO TDC/COMPRESSION [1][2]Reassembly

7. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY [1][2]Reassembly

8. INSTALL NO. 1 CHAIN SUB-ASSEMBLY RH [1][2]Reassembly

9. INSTALL NO. 1 CHAIN VIBRATION DAMPER RH [1][2]Reassembly

10. INSTALL NO. 1 CHAIN TENSIONER SLIPPER RH [1][2]Reassembly

11. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY RH [1][2]Reassembly

12. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY [1][2]Reassembly

13. INSTALL NO. 1 CHAIN SUB-ASSEMBLY LH [1][2]Reassembly

14. INSTALL NO. 1 CHAIN TENSIONER SLIPPER LH [1][2]Reassembly

15. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY LH [1][2]Reassembly

16. INSTALL NO. 1 CHAIN VIBRATION DAMPER LH [1][2]Reassembly

17. TIGHTEN CAMSHAFT TIMING GEAR [1][2]Reassembly

18. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION [1][2]Reassembly

19. INSTALL WATER INLET PIPE [1][2]Installation

20. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY [1][2]Installation

21. INSTALL SPARK PLUG TUBE GASKET [1][2]Reassembly

22. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH [1][2]Installation

23. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH [1][2]Installation

24. INSTALL IGNITION COIL ASSEMBLY [1][2]Installation

25. INSTALL CRANKSHAFT TIMING GEAR KEY [1][2]Reassembly

26. CONNECT WIRE HARNESS CLAMP BRACKET [1][2]Installation

27. INSTALL CRANKSHAFT PULLEY [1][2]Installation

28. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY [1][2]Installation

29. INSTALL WATER PUMP PULLEY [1][2]Installation

30. INSTALL WATER INLET HOUSING [1][2]Installation

31. INSTALL AIR PIPE SUB-ASSEMBLY [1][2]Installation

32. INSTALL NO. 1 ENGINE COVER Installation

33. INSTALL NO. 2 ENGINE COVER Installation

34. INSTALL FRONT WATER BY-PASS JOINT [1][2]Installation

35. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY [1][2]Installation

36. INSTALL NO. 1 WATER BY-PASS HOSE [1][2]Installation

37. INSTALL GENERATOR ASSEMBLY Installation

38. CONNECT OIL COOLER PIPE ASSEMBLY Installation

39. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE Installation

40. CONNECT VANE PUMP ASSEMBLY [1][2]Installation

41. INSTALL INTAKE MANIFOLD Installation

42. INSTALL OIL FILTER BRACKET (w/o Oil Cooler) [1][2]Installation

43. INSTALL OIL FILTER BRACKET (w/ Oil Cooler) Installation

44. INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) Installation

45. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY (w/ Oil Cooler) [1][2]Installation

46. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY Installation

47. INSTALL OIL FILTER ELEMENT Replacement

48. CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY [1][2]Installation

49. CONNECT COOLER COMPRESSOR ASSEMBLY [1][2]Installation

50. CONNECT NO. 2 WATER BY-PASS PIPE [1][2]Installation

51. CONNECT AIR PUMP HOSE AND WIRE HARNESS [1][2]Installation

52. CONNECT ENGINE WIRE [1][2]Installation

53. INSTALL RADIATOR ASSEMBLY [1][2]Installation

54. INSTALL FAN SHROUD Installation

55. INSTALL NO. 2 RADIATOR HOSE
56. INSTALL NO. 1 RADIATOR HOSE
57. INSTALL AIR CLEANER ASSEMBLY Installation

58. INSTALL AIR CLEANER HOSE ASSEMBLY Installation

59. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation

60. INSTALL HOOD TO COWL TOP SEAL Installation

61. INSTALL FRONT FENDER MAIN SEAL LH Installation

62. INSTALL FRONT FENDER MAIN SEAL RH Installation

63. INSTALL FRONT WIPER ARM LH Installation

64. INSTALL FRONT WIPER ARM RH Installation

65. INSTALL RADIATOR SIDE DEFLECTOR RH (w/o Air Cooled Transmission Oil Cooler) Installation

66. INSTALL RADIATOR SIDE DEFLECTOR LH Installation

67. INSTALL RADIATOR GRILLE Installation

68. ADD ENGINE OIL Replacement

69. ADD ENGINE COOLANT Service and Repair

70. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

71. INSPECT FOR OIL LEAK Replacement

72. INSPECT FOR COOLANT LEAK Testing and Inspection

73. INSPECT ENGINE OIL LEVEL Testing and Inspection

74. INSPECT IGNITION TIMING Engine

75. INSPECT ENGINE IDLE SPEED Engine

76. INSTALL FRONT FENDER APRON SEAL FRONT RH Installation

77. INSTALL FRONT FENDER APRON SEAL FRONT LH Installation

78. INSTALL NO. 2 ENGINE UNDER COVER Installation

79. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY Installation

80. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH Installation

81. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH Installation

82. INSTALL V-BANK COVER SUB-ASSEMBLY Installation

83. INSTALL UPPER RADIATOR SUPPORT SEAL Installation

84. INSTALL ENGINE ROOM SIDE COVER LH Installation

85. INSTALL ENGINE ROOM SIDE COVER RH Removal