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Installation [04/2013 - 08/2015]: Procedure

WARNING: This page is about a different car, the 2015 Lexus IS 250 and 2014 Lexus IS 250. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Secure the camshaft between aluminum plates in a vise.
      NOTE:

      Be careful not to damage the camshaft in the vise.

    2. Put the camshaft timing gear assembly and camshaft together by aligning the pin hole and straight pin.
      GTY468116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Pin Hole
      *2 Straight Pin
    3. Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the hole.
      NOTE:

      Be sure not to turn the camshaft timing gear assembly in the retard direction.

    4. Apply a small amount of engine oil to the threads and seat section of the flange bolt.
    5. Install the flange bolt while holding the camshaft.

      Torque: 100 N.m (1020 kgf/cm, 74 ft.lbf) 

    6. Check the lock of the camshaft timing gear assembly.
      1. Secure the camshaft in place and confirm that the camshaft timing gear assembly is locked.
        NOTE:

        Be careful not to damage the camshaft.

  2. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. Clamp the camshaft in a vise between aluminum plates.
      NOTE:

      Be careful not to damage the camshaft in the vise.

    2. Put the camshaft timing exhaust gear assembly and camshaft together by aligning the pin hole and straight pin.
      GTY464265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Pin Hole
      *2 Straight Pin
    3. Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the hole.
      NOTE:

      Be sure not to turn the camshaft timing exhaust gear assembly in the advanced direction.

    4. Apply a small amount of engine oil to the threads and seat section of the flange bolt.
    5. Install the flange bolt while holding the camshaft.

      Torque: 100 N.m (1020 kgf/cm, 74 ft.lbf) 

    6. Check the lock of the camshaft timing exhaust gear assembly.
      1. Secure the camshaft in place and confirm that the camshaft timing gear assembly is locked.
        NOTE:

        Be careful not to damage the camshaft.

  3. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY 
    1. Check that the notch is aligned with the "0" timing mark of the timing chain or belt cover sub-assembly.
      GTY463216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Notch
    2. Align the mark plate (yellow) with the timing mark of the camshaft timing gear assembly as shown in the illustration and install the No. 2 chain sub-assembly to the camshaft timing gear assembly.
      GTY457714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Timing Mark
      *2 Mark Plate (yellow)
      *a Align
    3. Clean the camshaft housing sub-assembly LH and No. 3 camshaft journals, and apply engine oil to them.
    4. Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.
      GTY470513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap
    5. Install the chain sub-assembly to the No. 3 camshaft sub-assembly, and then install the No. 3 camshaft sub-assembly to the camshaft housing sub-assembly LH.
      GTY459431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Place chain sub-assembly on camshaft timing gear assembly

      HINT: 

      • Place the chain sub-assembly on the camshaft timing gear assembly but do not engage the teeth of the sprocket and the chain sub-assembly.
      • Install the No. 3 camshaft sub-assembly so that the timing mark is facing upward.
  4. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY 
    1. Clean the camshaft housing sub-assembly LH and No. 4 camshaft journals, and apply engine oil to them.
    2. Pass the No. 4 camshaft sub-assembly through the No. 2 chain sub-assembly from the front of the vehicle, align the mark plate (yellow) with the timing mark and install the No. 2 chain sub-assembly to the camshaft timing exhaust gear assembly LH.
      GTY462146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Mark Plate (yellow)
      *2 Timing Mark
    3. While lifting up the No. 4 camshaft sub-assembly, pass the No. 3 chain tensioner assembly through the No. 2 chain sub-assembly and set it in place.
      GTY465989Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the No. 4 camshaft sub-assembly to the camshaft housing sub-assembly LH, and then install the No. 3 chain tensioner assembly with the bolt.

      Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

  5. INSTALL CAMSHAFT BEARING CAP (for Bank 2) 
    1. Clean the camshaft bearing caps and apply engine oil to them.
    2. Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.
      GTY465243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap
    3. Check the marks and numbers on the camshaft bearing caps, and then remove the service bolts and washers in the order shown in the illustration.

      Immediately after removing the service bolts and washers in the locations for the camshaft bearing caps, install the camshaft bearing caps with the bolts in the order shown in the illustration.

      Fig 1: Camshaft Bearing Cap Bolts Tightening Sequence (Bank 2)
      GTY456937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Service Bolt and Washers (used to temporarily secure the camshaft housing sub-assembly LH)
      *a Remove the service bolts and washers used to temporarily secure the camshaft housing sub-assembly LH
      *b Part to be Installed
      Bolt A
      Bolt B

      for bolt A 

      Torque: 28 N.m (286 kgf/cm, 21 ft.lbf) 

      for bolt B 

      Torque: 16 N.m (163 kgf/cm, 12 ft.lbf) 

      NOTE:
      • Be sure to follow the numerical order when performing this procedure.
      • Do not drop the service bolts and washers into the cylinder head LH.
    4. Check the torque of each bolt again.
  6. INSTALL CHAIN SUB-ASSEMBLY (for Bank 2) 
    1. Align the paint marks on the camshaft timing gear assembly and chain sub-assembly, and install the chain sub-assembly to the camshaft timing gear assembly.
      GTY462597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Paint Mark

      HINT: 

      If the paint marks are not aligned, align them by turning the camshaft slightly.

  7. INSTALL CAMSHAFT 
    1. Turn the crankshaft clockwise until it is in the position shown in the illustration so that the chain sub-assembly can be installed easily.
      GTY469395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 5 to 10°
      NOTE:

      When turning the crankshaft, engine oil may spray out of the oil holes.

    2. Align the mark plate (yellow) with the timing mark of the camshaft timing gear assembly as shown in the illustration and install the No. 2 chain sub-assembly to the camshaft timing gear assembly.
      GTY466676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Timing Mark
      *2 Mark Plate (yellow)
      *a Align
    3. Clean the camshaft housing sub-assembly RH and camshaft journals and apply engine oil to them.
    4. Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.
      GTY465243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap
    5. Install the chain sub-assembly to the camshaft, and then install the camshaft to the camshaft housing sub-assembly RH.
      GTY468799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Place chain sub-assembly on camshaft timing gear

      HINT: 

      • Place the chain sub-assembly on the camshaft timing gear assembly but do not engage the teeth of the sprocket and the chain sub-assembly.
      • Install the camshaft so that the timing mark is facing upward.
  8. INSTALL NO. 2 CAMSHAFT 
    1. Clean the camshaft housing sub-assembly RH and No. 2 camshaft journals, and apply engine oil to them.
    2. Pass the No. 2 camshaft through the No. 2 chain sub-assembly from the front of the vehicle, align the mark plate (yellow) with the timing mark and install the No. 2 chain sub-assembly to the camshaft timing exhaust gear assembly RH.
      GTY457504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Mark Plate (yellow)
      *2 Timing Mark
    3. While lifting up the No. 2 camshaft, pass the No. 2 chain tensioner assembly through the No. 2 chain sub-assembly and set it in place.
      GTY465991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the No. 2 camshaft to the camshaft housing sub-assembly RH, and then install the No. 2 chain tensioner assembly with the bolt.

      Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

  9. INSTALL CAMSHAFT BEARING CAP (for Bank 1) 
    1. Clean the camshaft bearing caps and apply engine oil to them.
    2. Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.
      GTY465243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap
    3. Check the marks and numbers on the camshaft bearing caps, and then remove the service bolts and washers in the order shown in the illustration.

      Immediately after removing the service bolts and washers in the locations for the bearing caps, install the bearing caps with the bolts in the order shown in the illustration.

      Fig 2: Camshaft Bearing Cap Bolts Tightening Sequence (Bank 1)
      GTY459901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Service Bolt and Washers (used to temporarily secure the camshaft housing sub-assembly RH)
      *a Remove the service bolts and washers to temporarily secure the camshaft housing sub-assembly RH
      *b Part to be Installed
      Bolt A
      Bolt B

      for bolt A 

      Torque: 28 N.m (286 kgf/cm, 21 ft.lbf) 

      for bolt B 

      Torque: 16 N.m (163 kgf/cm, 12 ft.lbf) 

      NOTE:
      • Be sure to follow the numerical order when performing this procedure.
      • Do not drop the service bolts and washers into the cylinder head sub-assembly.
    4. Check the torque of each bolt again.
  10. INSTALL CHAIN SUB-ASSEMBLY (for Bank 1) 
    1. Align the paint marks on the camshaft timing gear assembly and chain sub-assembly, and install the chain sub-assembly to the camshaft timing gear assembly.
      GTY460646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Paint Mark

      HINT: 

      If the paint marks are not aligned, align them by turning the camshaft slightly.

  11. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Turn the crankshaft counterclockwise 30° past the "0" timing mark, and then turn it clockwise to align the notch with the "0" timing mark.
      GTY457050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 0°
      *b 30°
    2. Turn the crankshaft slightly to eliminate the slack in the chain sub-assembly.

      HINT: 

      Make sure there is some slack in the chain around the area where the No. 1 chain tensioner assembly is installed.

    3. While turning the stopper plate of the No. 1 chain tensioner assembly clockwise, push in the plunger of the No. 1 chain tensioner assembly as shown in the illustration.
      GTY456672Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Stopper Plate
      *2 Hexagon Wrench
      *a Push
    4. While turning the stopper plate of the No. 1 chain tensioner assembly counterclockwise, insert a hexagon wrench into the holes in the stopper plate and No. 1 chain tensioner assembly to secure the stopper plate in place.
    5. Install the No. 1 chain tensioner assembly with the 2 bolts.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

    6. Remove the hexagon wrench from the No. 1 chain tensioner assembly.
  12. INSPECT VALVE TIMING 
    1. Check that each camshaft timing mark is positioned as shown in the illustration.
      GTY468056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Timing Mark - -
      *a Viewpoint - -
      NOTE:
      • Check each timing mark from a viewpoint directly in line with the center of the camshaft and the timing mark on each camshaft timing gear assembly.
      • If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.

      HINT: 

      For Intake Camshaft: Be sure to check mark A at the point when marks B, C and D are positioned in line.

      If the marks are checked from any other viewpoint, they cannot be checked correctly.

      GTY463507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. If the valve timing is misaligned, reinstall the chain sub-assembly again.
    3. Turn the crankshaft 2 revolutions, set the No. 1 cylinder to TDC/compression and check the timing marks again.
  13. INSTALL TIMING CHAIN COVER PLATE 
    1. Install a new gasket and the timing chain cover plate with the 4 bolts.

      Torque: 9.1 N.m (93 kgf/cm, 81 in.lbf) 

  14. INSTALL SPARK PLUG TUBE GASKET 

    Refer to PROCEDURE - Step 49

  15. POUR ENGINE OIL 

    HINT: 

    Before installing the cylinder head cover sub-assemblies, pour engine oil into the oil holes shown in the illustration until the oil holes are filled with engine oil.

    GTY101239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain or belt cover sub-assembly or cylinder head cover sub-assembly.
    2. Apply seal packing as shown in the illustration.
      GTY469076Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 timing chain cover sub-assembly
      *2 camshaft housing sub-assembly RH
      *a 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      *b 5.0 to 10.0 mm (0.197 to 0.394 in.)
      Seal Packing

      Seal packing

      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      NOTE:
      • Remove any oil from the contact surface.
      • Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes after 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.
    3. Install 3 new gaskets to the No. 1, No. 2 and No. 7 camshaft bearing caps.
    4. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
    5. Apply adhesive to the threads of the 11 bolts indicated by the black arrows in the illustration.
      GTY464146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt with cylinder head cover seal washer
      Apply adhesive to these bolts

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      NOTE:

      Tighten the bolts within 3 minute after applying adhesive.

    6. Install the cylinder head cover sub-assembly with the 14 bolts and 2 new cylinder head cover seal washers.

      for Bolt A 

      Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

      except Bolt A 

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

    7. Attach the clamps and connect the connectors to the cylinder head cover sub-assembly.
  17. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH 
    1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head LH, timing chain or belt cover sub-assembly or cylinder head cover sub-assembly LH.
    2. Apply seal packing as shown in the illustration.
      GTY461469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 timing chain cover sub-assembly
      *2 camshaft housing sub-assembly LH
      *a 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      *b 5 to 10 mm (0.197 to 0.394 in.)
      Seal Packing

      Seal packing

      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      NOTE:
      • Remove any oil from the contact surface.
      • Install the head cover sub-assembly LH within 3 minutes and tighten the bolts within 15 minutes after 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.
    3. Install 3 new gaskets to the No. 3, No. 4 and No. 7 camshaft bearing caps.
    4. Install a new cylinder head cover gasket LH to the cylinder head cover sub-assembly LH.
    5. Apply adhesive to the threads of the 10 bolts indicated by the black arrows in the illustration.
      GTY467504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt with cylinder head cover seal washer
      Apply adhesive to these bolts

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      NOTE:

      Tighten the bolts within 3 minute after applying adhesive.

    6. Install the cylinder head cover sub-assembly LH with the 12 bolts and a new cylinder head cover seal washer.

      for bolt A 

      Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

      except bolt A 

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

    7. Attach the clamps and connect the connectors to the cylinder head cover sub-assembly LH.
  18. INSTALL NO. 2 OIL PIPE 

    Refer to PROCEDURE - Step 63

  19. INSTALL NO. 1 OIL PIPE 
    1. Install the oil control valve filter LH to the oil pipe union. Install 2 new gaskets and temporarily install the No. 1 oil pipe on the cylinder head cover sub-assembly LH side with the oil pipe union.
      NOTE:
      • Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.
      • Do not touch the mesh when installing the oil control valve filter LH.
    2. Install a new gasket and temporarily install the No. 1 oil pipe on the cylinder head LH side with the oil check valve bolt.
    3. Using a 17 mm ball joint lock nut wrench, tighten the oil pipe union on the cylinder head cover sub-assembly LH side.

      Torque: 60 N.m (612 kgf/cm, 44 ft.lbf) 

      NOTE:

      Use the formula to calculate special torque values for situations where a ball joint lock nut wrench is combined with a torque wrench.

      Refer to PRECAUTION [04/2013 - 08/2015]

      GTY462565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten the oil check valve bolt on the cylinder head LH side.

      Torque: 60 N.m (612 kgf/cm, 44 ft.lbf) 

      NOTE:

      If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.

  20. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE 

    Refer to PROCEDURE - Step 3

  21. INSTALL AIR CLEANER CASE SUB-ASSEMBLY 

    See step  70

  22. INSTALL SPARK PLUG 

    Refer to PROCEDURE - Step 1

  23. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  24. INSTALL INJECTOR DRIVER 

    Refer to PROCEDURE - Step 1

  25. INSTALL NO. 1 ENGINE COVER 

    Refer to PROCEDURE - Step 2

  26. INSTALL GENERATOR ASSEMBLY 

    Refer to INSTALLATION [04/2013 - 08/2015]

  27. INSTALL FUEL PUMP ASSEMBLY 

    Refer to INSTALLATION [04/2013 - 08/2015]

  28. INSTALL BATTERY 

    Refer to PROCEDURE - Step 3

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