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Installation [08/2015 - ]: Procedure

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  1. INSTALL NO. 2 CAMSHAFT BEARING 

    Refer to PROCEDURE - Step 22

  2. INSTALL NO. 1 CAMSHAFT BEARING 

    Refer to PROCEDURE - Step 21

  3. INSTALL OIL CONTROL VALVE FILTER 

    Refer to PROCEDURE - Step 23

  4. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 

    HINT: 

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

    Refer to INITIALIZATION [08/2015 - 09/2018] , or refer to INITIALIZATION [09/2018 - 09/2019] , or refer to INITIALIZATION [09/2019 - ]

    1. Using SST, grip the hexagonal portion, and then secure the SST and No. 2 camshaft in a vise as shown in the illustration.
      GTY616478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hexagonal Portion
      • SST: 09212-31010 
      NOTE:
      • Do not damage the No. 2 camshaft.
      • Never grip areas other than the hexagonal portion, as this may cause damage.
    2. Align the knock pin of the No. 2 camshaft with the knock pin hole of the camshaft timing exhaust gear assembly and attach the camshaft timing exhaust gear assembly to the No. 2 camshaft.
      GTY509728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin Hole
      *b Knock Pin
      NOTE:

      Do not forcefully press the camshaft timing exhaust gear assembly. Otherwise, the tip of knock pin of the No. 2 camshaft may damage the seal surface of the camshaft timing exhaust gear assembly, leading to poor sealing.

    3. Check that there is no clearance between the camshaft timing exhaust gear assembly and No. 2 camshaft flange.
      GTY499465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Camshaft Timing Exhaust Gear Assembly
      *a Incorrect
      *b Correct
      *c No. 2 Camshaft Flange
      *d No Clearance
    4. Secure the No. 2 camshaft in place by hand, and then install the bolt of the camshaft timing exhaust gear assembly by hand.
    5. Tighten the bolt.

      Torque: 85 N.m (867 kgf/cm, 63 ft.lbf) 

      NOTE:
      • Do not damage the No. 2 camshaft and camshaft timing exhaust gear assembly.
      • Do not disassemble the camshaft timing exhaust gear assembly.
  5. SET NO. 1 CYLINDER TO TDC/COMPRESSION 
    1. Turn the crankshaft until the timing mark (groove) of the crankshaft pulley assembly and the timing mark "0" of the timing chain cover assembly are aligned.
      GTY518376Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark "0"
      *b Timing Mark (Groove)
  6. INSTALL NO. 2 CAMSHAFT 
    NOTE:

    When turning the No. 2 camshaft with the chain sub-assembly removed, take care to prevent the piston and valve from contacting and damaging the part.

    HINT: 

    Perform "Inspection After Repair" after replacing the No. 2 camshaft.

    Refer to INITIALIZATION [08/2015 - 09/2018] , or refer to INITIALIZATION [09/2018 - 09/2019] , or refer to INITIALIZATION [09/2019 - ]

    1. Check that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.
      GTY497302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap
    2. Clean the camshaft journals.
    3. Apply a light coat of engine oil to the No. 2 camshaft journals and camshaft housing sub-assembly.
    4. Clean the thrust surface of the No. 2 camshaft and apply engine oil.
      GTY667491Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Thrust Surface
    5. Align the paint mark of the chain sub-assembly that was put on when the chain sub-assembly was removed and the timing mark (groove) of the camshaft timing exhaust gear assembly. Then install the No. 2 camshaft and camshaft timing exhaust gear assembly.
      GTY623550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
      *b Timing Mark (Groove)
  7. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 

    HINT: 

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

    Refer to INITIALIZATION [08/2015 - 09/2018] , or refer to INITIALIZATION [09/2018 - 09/2019] , or refer to INITIALIZATION [09/2019 - ]

    1. Align the paint mark of the chain sub-assembly that was put on when the chain sub-assembly was removed and the timing mark (groove) of the camshaft timing gear assembly. Then install the camshaft timing gear assembly.
      GTY511206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
      *b Timing Mark (Groove)
      NOTE:

      Do not disassemble the camshaft timing gear assembly.

  8. INSTALL CAMSHAFT 
    NOTE:

    When turning the camshaft with the chain sub-assembly removed, take care to prevent the piston and valve from contacting and damaging the part.

    HINT: 

    Perform "Inspection After Repair" after replacing the camshaft.

    Refer to INITIALIZATION [08/2015 - 09/2018] , or refer to INITIALIZATION [09/2018 - 09/2019] , or refer to INITIALIZATION [09/2019 - ]

    1. Check that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.
      GTY497302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap
    2. Clean the camshaft journals.
    3. Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly.
    4. Clean the thrust surface of the camshaft and apply engine oil.
      GTY667491Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Thrust Surface
    5. Put the camshaft timing gear assembly and camshaft together with the knock pin of the knock pin hole.
      GTY657700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin Hole
      *b Knock Pin
    6. Turn the camshaft timing gear assembly clockwise while pushing it gently toward the camshaft. When the knock pin fits into the knock pin hole, push to ensure a good fit.
      NOTE:

      Do not forcefully press the camshaft timing gear assembly. Otherwise, the tip of knock pin of the camshaft may damage the seal surface of the camshaft timing gear assembly, leading to poor sealing.

    7. Check that there is no clearance between the camshaft timing gear assembly and portion A of the camshaft indicated in the illustration.
      GTY520814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Camshaft Timing Gear Assembly
      *a Incorrect
      *b Correct
      *c Portion A of Camshaft
      *d No Clearance
  9. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT 
    NOTE:

    There are different types of camshaft timing gear bolts. Make sure to check the identification mark on the bolt and use the specified torque value for the bolt when tightening.

    GTY669128Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Identification Mark
    IDENTIFICATION MARK

    Type Identification Mark
    A A
    B C
    1. Apply engine oil to the areas of the camshaft timing gear bolt indicated in the illustration.
      GTY504339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the camshaft timing gear bolt to the camshaft.

      HINT: 

      When temporarily installing the camshaft timing gear bolt, make sure that it is screwed in approximately 3 threads.

  10. INSTALL CAMSHAFT BEARING CAP 
    1. Place the No. 1, No. 2, No. 3 and No. 4 camshaft bearing caps to the camshaft housing sub-assembly.
      GTY624782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Camshaft Bearing Cap
      *2 No. 2 Camshaft Bearing Cap
      *3 No. 3 Camshaft Bearing Cap
      *4 No. 4 Camshaft Bearing Cap
    2. Install the 10 camshaft bearing cap bolts in the order shown in the illustration.

      Torque: 27 N.m (275 kgf/cm, 20 ft.lbf) 

    3. Install the 11 camshaft bearing cap bolts in the order shown in the illustration.
      Fig 1: Camshaft Bearing Cap Tightening Sequence
      GTY511050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  11. TIGHTEN CAMSHAFT TIMING GEAR BOLT 
    1. Check that the chain sub-assembly is loose as shown in the illustration.
      GTY678888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Use a wrench to hold the hexagonal portion of the camshaft.
      GTY659962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
    3. Tighten the camshaft timing gear bolt.

      Type A 

      Torque: 120 N.m (1224 kgf/cm, 89 ft.lbf) 

      Type B 

      Torque: 95 N.m (969 kgf/cm, 70 ft.lbf) 

      NOTE:

      Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.

    4. Check that each timing mark (groove) of the camshaft timing gear assembly and camshaft timing exhaust gear assembly are aligned with each paint mark located as shown in the illustration.
      GTY667937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
      *b Timing Mark (Groove)
  12. ADD ENGINE OIL 

    Refer to PROCEDURE - Step 32

  13. INSTALL TIMING CHAIN GUIDE 

    Refer to PROCEDURE - Step 38

  14. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Turn the crankshaft approximately 15° clockwise.
      GTY670838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Approximately 15°
    2. Temporarily install a new gasket and the No. 1 chain tensioner assembly to the cylinder block sub-assembly with the nut and bolt.
      NOTE:

      Make sure not to drop the gasket inside the timing chain cover assembly.

    3. Tighten the nut and bolt.

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

    4. Remove the pin from the stopper plate.
  15. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION 
    1. Turn the crankshaft until the timing mark (groove) of the crankshaft pulley assembly and the timing mark "0" of the timing chain cover assembly are aligned.
      GTY616654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark (Groove) *d Timing Mark "0"
      *e Paint Mark - -
    2. Check that each timing mark (groove) of the camshaft timing gear assembly and camshaft timing exhaust gear assembly are aligned with each paint mark located as shown in the illustration.
  16. INSTALL TIMING CHAIN COVER PLATE 

    Refer to PROCEDURE - Step 40

  17. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY 

    Refer to PROCEDURE - Step 1

  18. INSTALL VACUUM PUMP ASSEMBLY 

    Refer to INSTALLATION [08/2015 - ]

  19. INSTALL CAMSHAFT BEARING CAP OIL HOLE GASKET 
    1. Apply a light coat of engine oil to a new gasket and new camshaft bearing cap oil hole gasket.
    2. Install the gasket to the No. 2 camshaft bearing cap.
    3. Install the camshaft bearing cap oil hole gasket to the No. 1 camshaft bearing cap.
  20. INSTALL CYLINDER HEAD COVER GASKET 
    1. Install a new cylinder head cover gasket and new No. 2 cylinder head cover gasket to the cylinder head cover sub-assembly.
  21. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Apply seal packing as shown in the illustration.
      GTY633817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Timing Chain Cover Assembly
      *2 Camshaft Housing Sub-assembly
      *a Application Width: 8.0 mm (0.315 in.)
      *b Application Width: 5.0 mm (0.197 in.)
      *c Seal Diameter: 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      Seal Packing

      Seal packing

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

      Standard seal diameter

      2.0 to 3.0 mm (0.0787 to 0.118 in.)

      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 within 2 hours after installation.
    2. Apply a light coat of engine oil to the 2 camshaft position sensors.
    3. Temporarily install the cylinder head cover sub-assembly and the 2 camshaft position sensors with the 21 bolts.
    4. Tighten the 21 bolts in the order shown in the illustration.
      Fig 2: Cylinder Head Cover Sub-Assembly Bolt Tightening Sequence
      GTY648360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  22. INSTALL NO. 3 VENTILATION HOSE 
    1. Connect the No. 3 ventilation hose with the clip as shown in the illustration.
      GTY678810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Upper Side
      *b 90°

      HINT: 

      Install the clip so that it is positioned as shown in the illustration.

  23. INSTALL NO. 1 TURBO WATER PIPE 
    1. Install the No. 1 turbo water pipe to the cylinder head cover sub-assembly with the 3 bolts.
      GTY678509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Turbo Water By-pass Hose
      *2 No. 2 Turbo Water By-pass Hose
      *3 No. 3 Turbo Water By-pass Hose
      *4 No. 4 Turbo Water By-pass Hose
      *5 No. 1 Turbo Water Pipe
      *a Upper Side
      *b RH Side

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

    2. Connect the No. 1, No. 2, No. 3 and No. 4 turbo water by-pass hoses with the 4 clips as shown in the illustration.

      HINT: 

      Install the clips so that they are positioned as shown in the illustration.

  24. CONNECT ENGINE WIRE 
    1. Connect the engine wire to the cylinder head cover sub-assembly with the bolt.

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

    2. Attach the clamp and connect the No. 3 ventilation hose to the engine wire.
    3. Connect the connector to the air fuel ratio sensor.
    4. Connect the 2 connectors to the 2 camshaft position sensors.
  25. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  26. CONNECT NO. 4 VENTILATION HOSE 

    Refer to PROCEDURE - Step 2

  27. INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) 

    Refer to INSTALLATION [08/2015 - ]

  28. INSTALL FAN SHROUD 

    Refer to INSTALLATION [08/2015 - ]

  29. INSPECT FOR ENGINE OIL LEAK 

    Refer to PROCEDURE - Step 5 [08/2015 - 09/2020] , or refer to PROCEDURE - Step 5 [09/2020 - 11/2021] , or refer to PROCEDURE - Step 5 [11/2021 - 09/2022] , or refer to PROCEDURE - Step 5 [09/2022 - ]

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