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Installation [08/2020 - ]: Procedure

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  1. INSTALL CAMSHAFT 

    HINT: 

    Perform "Inspection After Repair" after replacing the camshaft, No. 2 camshaft, camshaft timing gear assembly and camshaft timing exhaust gear assembly.

    Refer to INITIALIZATION [08/2020 - ]

    1. Turn the crankshaft clockwise to align the timing mark (cutout) on the crankshaft pulley assembly with the "0" timing mark on the No. 2 timing chain cover assembly.
      GTY939414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a "0" Timing Mark
      *b Timing Mark
    2. Check that the No. 1 valve rocker arm sub-assembly is correctly installed as shown in the illustration.
      GTY924635Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap
    3. Clean the camshaft housing sub-assembly and the cams and journals of the camshaft and No. 2 camshaft, and then apply engine oil to them.
    4. Apply a light coat of engine oil to the journals of the camshaft and install the camshaft to the camshaft housing sub-assembly.
    5. Apply a light coat of engine oil to the journals of the No. 2 camshaft and install the No. 2 camshaft to the camshaft housing sub-assembly.
    6. Set the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, 2 No. 3 camshaft bearing caps and No. 4 camshaft bearing cap as shown in the illustration.
      Fig 1: Camshaft Bearing Cap (14 Bolts) Tightening Sequence [08/2020 - ]
      GTY873504Courtesy 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
    7. Uniformly tighten the 14 bolts in the order shown in the illustration.

      Torque: 28.5 N*m (291 kgf*cm, 21 ft.*lbf) 

    8. Uniformly tighten the 8 bolts in the order shown in the illustration.

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

      Fig 2: Camshaft Bearing Cap (8 Bolts) Tightening Sequence [08/2020 - ]
      GTY879079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Set the camshaft timing gear assembly and camshaft timing exhaust gear assembly to the chain sub-assembly as shown in the illustration.
      GTY904190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Align the timing mark on the camshaft timing gear assembly with the paint mark on the chain sub-assembly.
      GTY942101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
      *b Timing Mark
    11. Align the timing mark on the camshaft timing exhaust gear assembly with the paint mark on the chain sub-assembly.
      GTY891679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
      *b Timing Mark
    12. Using the hexagonal portion of the camshaft, install the camshaft timing gear assembly to the camshaft.
      GTY909938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin
      NOTE:

      Do not damage the camshaft housing sub-assembly, cylinder head sub-assembly and spark plug tube.

    13. Check that the knock pin matches the pin hole from the No. 2 timing chain cover assembly side.
    14. Using a 10 mm bi-hexagon socket wrench, temporarily install the camshaft timing gear assembly with the bolt.

      HINT: 

      Temporarily install the bolt enough that the camshaft timing gear assembly does not detach from the knock pin of the camshaft.

    15. Type A:
      1. Using the hexagonal portion of the No. 2 camshaft, install the camshaft timing exhaust gear assembly to the No. 2 camshaft.
        GTY904151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Temporarily install the 2 bolts.

        HINT: 

        The 2 bolts can only be installed as shown in the illustration if the knock pin on the No. 2 camshaft and the pin hole on the camshaft timing exhaust gear assembly match. If the 2 bolts cannot be installed, the knock pin and pin hole do not match.

    16. Type B:
      1. Using the hexagonal portion of the No. 2 camshaft, install the camshaft timing exhaust gear assembly to the No. 2 camshaft.
        GTY998385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Temporarily install the 2 bolts.

        HINT: 

        The 2 bolts can only be installed as shown in the illustration if the knock pin on the No. 2 camshaft and the pin hole on the camshaft timing exhaust gear assembly match. If the 2 bolts cannot be installed, the knock pin and pin hole do not match.

    17. Check the status of the camshaft timing gear assembly and camshaft timing exhaust gear assembly temporarily installed to each camshaft.
      GTY905154Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Chain Vibration Damper
      1. Camshaft timing gear assembly side:

        Check that the chain sub-assembly does not overlap the No. 1 chain vibration damper as shown in the illustration.

        NOTE:

        If the chain sub-assembly overlaps the No. 1 chain vibration damper, install it again.

      2. Camshaft timing exhaust gear assembly side:

        Check that the chain sub-assembly does not overlap the chain tensioner slipper as shown in the illustration.

        NOTE:

        If the chain sub-assembly overlaps the chain tensioner slipper, install it again.

        GTY921525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Chain Tensioner Slipper
    18. Using the hexagonal portion of the camshaft, hold the camshaft.
      NOTE:
      • Do not damage the camshaft housing sub-assembly, cylinder head sub-assembly and spark plug tube.
      • Do not disassemble the camshaft timing gear assembly.
      GTY943501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
    19. Using a 10 mm bi-hexagon socket wrench, tighten the bolt on the camshaft timing gear assembly.

      Torque: 86 N*m (877 kgf*cm, 63 ft.*lbf) 

    20. Type A:
      1. Using a wrench, hold the hexagonal portion of the No. 2 camshaft.
        GTY925056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Hold
        NOTE:

        Be careful not to damage the camshaft housing sub-assembly, cylinder head sub-assembly and spark plug tube with the wrench.

      2. Using a 5 mm hexagon socket wrench, tighten the 2 bolts.

        Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 

    21. Type B:
      1. Using a wrench, hold the hexagonal portion of the No. 2 camshaft.
        GTY1204704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Hold
        NOTE:

        Be careful not to damage the camshaft housing sub-assembly, cylinder head sub-assembly and spark plug tube with the wrench.

      2. Using a 5 mm hexagon socket wrench, tighten the 2 bolts.

        Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 

    22. Check that the paint marks and timing marks are positioned as shown in the illustration.
      GTY846483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
      *b Timing Mark
    23. Using the hexagonal portion of the camshaft, check that the chain sub-assembly slackens when the camshaft is moved in the direction shown in the illustration.
      GTY847523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold - -
      Turn - -
      NOTE:

      If the chain sub-assembly remains tight and does not slacken, the chain tensioner slipper and No. 1 chain vibration damper may overlap the chain sub-assembly, so install them again.

    24. Remove the pin from the No. 1 chain tensioner assembly.
  2. INSTALL STRAIGHT SCREW PLUG 

    Refer to PROCEDURE - Step 43 [08/2020 - 08/2021] , or refer to PROCEDURE - Step 43 [08/2021 - ]

  3. SET NO. 1 CYLINDER TO TDC (COMPRESSION) 

    See step  [08/2020 - 08/2021], or see step  [08/2021 - 09/2022], or see step  [09/2022 - ]

  4. INSTALL FUEL PUMP LIFTER GUIDE 

    Refer to PROCEDURE - Step 29 [08/2020 - 08/2021] , or refer to PROCEDURE - Step 29 [08/2021 - ]

  5. INSTALL SPARK PLUG TUBE GASKET 

    Refer to PROCEDURE - Step 45 [08/2020 - 08/2021] , or refer to PROCEDURE - Step 45 [08/2021 - ]

  6. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 46 [08/2020 - 08/2021] , or refer to PROCEDURE - Step 46 [08/2021 - ]

  7. INSTALL VACUUM PUMP ASSEMBLY 

    Refer to INSTALLATION [08/2020 - ]

  8. INSTALL CAM TIMING CONTROL MOTOR O-RING 

    Refer to PROCEDURE - Step 1

  9. INSTALL CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY 

    Refer to PROCEDURE - Step 2

  10. INSTALL CAMSHAFT TIMING VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 1

  11. INSTALL O-RING 

    Refer to PROCEDURE - Step 1

  12. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY 

    Refer to PROCEDURE - Step 2

  13. INSTALL NO. 2 ENGINE COVER 

    Refer to PROCEDURE - Step 45 [08/2020 - 08/2021] , or refer to PROCEDURE - Step 44 [08/2021 - ]

  14. INSTALL NO. 3 BRAKE TUBE CLAMP 

    Refer to PROCEDURE - Step 5

  15. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  16. CONNECT ENGINE WIRE 
    1. Engage the 3 clamps to connect the engine wire.
      GTY904154Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the 6 connectors.
  17. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY 
    1. Engage the 2 clamps to connect the air conditioning tube and accessory assembly.
  18. INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) 

    Refer to INSTALLATION [08/2020 - 08/2021] , or refer to INSTALLATION [08/2021 - ]

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