Installation [08/2023 - ]: Procedure

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	No. 1 Valve Rocker Arm Sub-assembly	*2	Valve Lash Adjuster Assembly
   *3	Valve Stem Cap	-	-
   *a	"0" Timing Mark	*b	Timing Mark

   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.
   2. Check that the No. 1 valve rocker arm sub-assembly is correctly installed as shown in the illustration.
   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. Install the camshaft to the camshaft housing sub-assembly.
   5. Install the No. 2 camshaft to the camshaft housing sub-assembly.

2. Courtesy 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

   1. 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.
   2. Uniformly tighten the 14 bolts in the order shown in the illustration.

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

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

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

3. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Paint Mark	*b	Timing Mark
   *c	Knock Pin	-	-

   1. Set the camshaft timing gear assembly and camshaft timing exhaust gear assembly to the chain sub-assembly as shown in the illustration.
   2. Align the timing mark on the camshaft timing gear assembly with the paint mark on the chain sub-assembly.
   3. Align the timing mark on the camshaft timing exhaust gear assembly with the paint mark on the chain sub-assembly.
   4. Using the hexagonal portion of the camshaft, install the camshaft timing gear assembly to the camshaft.
      NOTE:

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

   5. Check that the knock pin matches the pin hole from the No. 2 timing chain cover assembly side.
   6. Using a 10 mm bi-hexagon socket wrench, temporarily install the camshaft timing gear assembly with the bolt.
   7. Using the hexagonal portion of the No. 2 camshaft, install the camshaft timing exhaust gear assembly to the No. 2 camshaft.
      NOTE:

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

   8. 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.

4. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1

   No. 1 Chain Vibration Damper

   *2

   Chain Tensioner Slipper

   1. Check the status of the camshaft timing gear assembly and camshaft timing exhaust gear assembly temporarily installed to each camshaft.

      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.

5. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Paint Mark	*b	Timing Mark
   *c	Hold	*d	Torque Wrench Fulcrum Length
   *e	Turn	-	-

   1. 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.
   2. Using SST and a 10 mm bi-hexagon socket wrench, tighten the bolt on the camshaft timing gear assembly.
      • SST: 09961-01270 

      Specified tightening torque 

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

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Refer to PRECAUTION [10/2022 - ]

      • When using SST (fulcrum length of 200 mm (7.87 in.)) + torque wrench (fulcrum length of 255 mm (10 in.)): 48 N.m (489 kgf/cm, 35 ft.lbf)
   3. Using the hexagonal portion of the No. 2 camshaft, hold the No. 2 camshaft.
      NOTE:

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

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

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

   5. Check that the paint marks and timing marks are positioned as shown in the illustration.

6. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Hold	*b	Pin
   	Turn	-	-

   1. 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.
      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.

   2. Remove the pin from the No. 1 chain tensioner assembly.
7. Perform "Inspection After Repair" after replacing the camshaft, No. 2 camshaft, camshaft timing gear assembly and camshaft timing exhaust gear assembly.

   Refer to INITIALIZATION [10/2022 - ]

Refer to PROCEDURE - Step 3

Refer to PROCEDURE - Step 5

Refer to INSTALLATION [08/2023 - ]

Refer to PROCEDURE - Step 3

Refer to PROCEDURE - Step 4

Refer to PROCEDURE - Step 6