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Installation [10/2015 - ]: Procedure

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  1. INSTALL NO. 2 CAMSHAFT BEARING 

    See step  22

  2. INSTALL NO. 1 CAMSHAFT BEARING 

    See step  21

  3. INSTALL OIL CONTROL VALVE FILTER 

    See 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 [10/2015 - 10/2018] , or refer to INITIALIZATION [10/2018 - 11/2019] , or refer to INITIALIZATION [11/2019 - ]

    1. Secure the No. 2 camshaft in a vise between aluminum plates.
      1. Using SST, grip the hexagonal portion, and then secure the SST and No. 2 camshaft in a vise as shown in the illustration.
        • SST: 09212-31010 
        GTY662181Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Hexagonal Portion
        NOTE:
        • Do not damage the No. 2 camshaft.
        • Never grip areas other than the hexagonal portion, as this may cause damage.
    2. Align and fit the knock pin of the No. 2 camshaft to the knock pin hole of the camshaft timing exhaust gear assembly.
      GTY509728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin Hole
      *b Knock Pin
    3. Check that there is no gap 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 gap
    4. Temporarily install the camshaft timing exhaust gear assembly to the No. 2 camshaft with the bolt.
    5. Tighten the bolt.

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

      NOTE:
      • Do not damage the No. 2 camshaft or 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 installing the camshaft housing sub-assembly, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position the camshafts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.

    HINT: 

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

    Refer to INITIALIZATION [10/2015 - 10/2018] , or refer to INITIALIZATION [10/2018 - 11/2019] , or refer to INITIALIZATION [11/2019 - ]

    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. Apply a light coat of engine oil to the No. 2 camshaft journals and camshaft housing sub-assembly.
    3. Align the paint mark of the chain sub-assembly and the timing mark (groove) of the camshaft timing exhaust gear assembly. Then install the No. 2 camshaft and camshaft timing exhaust gear assembly.
      GTY624789Courtesy 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 [10/2015 - 10/2018] , or refer to INITIALIZATION [10/2018 - 11/2019] , or refer to INITIALIZATION [11/2019 - ]

    1. Align the paint mark of the chain sub-assembly 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 installing the camshaft housing sub-assembly, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position the camshafts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.

    HINT: 

    Perform "Inspection After Repair" after replacing the camshaft.

    Refer to INITIALIZATION [10/2015 - 10/2018] , or refer to INITIALIZATION [10/2018 - 11/2019] , or refer to INITIALIZATION [11/2019 - ]

    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. Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly.
    3. Align and fit the knock pin of the camshaft to the knock pin hole of the camshaft timing gear assembly.
      GTY652757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin Hole
      *b Knock Pin
    4. Check that there is no gap between the camshaft timing gear assembly and camshaft flange.
      GTY520814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Camshaft Timing Gear Assembly
      *a Incorrect
      *b Correct
      *c Camshaft Flange
      *d No gap
  9. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT 
    NOTE:

    There are several different types of camshaft timing gear bolt. Make sure to check the identification mark to determine the tightening torque.

    IDENTIFICATION MARK

    Item Identification Mark
    Type A A
    Type B C
    GTY669128Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Identification Mark
    1. Apply engine oil to the areas of the camshaft timing gear bolt shown in the illustration.
      GTY646788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the camshaft timing gear bolt to the camshaft.

      HINT: 

      Temporarily install the camshaft timing gear bolt until 2 or 3 threads are screwed into the camshaft.

  10. INSTALL CAMSHAFT BEARING CAP 
    1. Place the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap to the camshaft housing sub-assembly.
    2. Install the 10 bolts in the order shown in the illustration.
      Fig 1: Camshaft Bearing Cap Bolts Tightening Sequence
      GTY504753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Install the 11 bolts in the order shown in the illustration.
      Fig 2: Camshaft Bearing Cap Bolts Tightening Sequence
      GTY511050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  11. TIGHTEN CAMSHAFT TIMING GEAR BOLT 
    NOTE:

    There are several different types of camshaft timing gear bolt. Make sure to check the identification mark to determine the tightening torque.

    IDENTIFICATION MARK

    Item Identification Mark
    Type A A
    Type B C
    GTY669128Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Identification Mark
    1. Check that the chain sub-assembly is loose as shown in the illustration.
      GTY684923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a wrench to hold the hexagonal portion of the camshaft, tighten the camshaft timing gear bolt.
      GTY641592Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn

      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.

    3. Check that each timing mark (groove) of the camshaft timing gear assembly and camshaft timing exhaust gear assembly is aligned with each paint mark as shown in the illustration.
      GTY649262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
      *b Timing Mark (Groove)
  12. ADD ENGINE OIL 

    See step  33

  13. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY 

    Refer to PROCEDURE - Step 1

  14. INSTALL TIMING CHAIN GUIDE 

    See step  38

  15. 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:

      Be careful not to drop the gasket into 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.
  16. CHECK NO. 1 CYLINDER 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.
      GTY655342Courtesy 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 is aligned with each paint mark as shown in the illustration.
  17. INSTALL TIMING CHAIN COVER PLATE 

    See step  40

  18. INSTALL CYLINDER HEAD COVER GASKET 

    See step  47

  19. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 

    See step  48

  20. INSTALL VACUUM PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 1

  21. 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.

      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.
      GTY643743Courtesy 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

      HINT: 

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

  22. 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. Engage the clamp and connect the No. 3 ventilation hose to the engine wire.
    3. Connect the air fuel ratio sensor connector.
    4. Connect the 2 connectors to the 2 camshaft position sensors.
  23. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 1

  24. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  25. CONNECT NO. 2 VENTILATION HOSE 
    1. Connect the No. 2 ventilation hose to the cylinder head cover sub-assembly and slide the clip to secure it.
      GTY647476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Upper Side
      *b 90°

      HINT: 

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

  26. CONNECT NO. 3 VENTILATION HOSE 
    1. Connect the No. 3 ventilation hose to the cylinder head cover sub-assembly and slide the clip to secure it.

      HINT: 

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

      GTY641144Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Upper Side
      *b 90°
  27. CONNECT NO. 4 VENTILATION HOSE 

    Refer to PROCEDURE - Step 2

  28. INSTALL FUEL PUMP ASSEMBLY (for High Pressure) 

    Refer to INSTALLATION [10/2015 - ]

  29. INSTALL RADIATOR ASSEMBLY 

    Refer to INSTALLATION [10/2015 - 11/2017] , or refer to INSTALLATION [11/2017 - ]

  30. CHECK ENGINE OIL LEVEL 

    Refer to PROCEDURE - Step 1 [10/2015 - 10/2023] , or refer to PROCEDURE - Step 1 [10/2023 - ]

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