Installation [12/2023 - ]: Procedure

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Timing Mark (Cutout)

   *b

   "0" Timing Mark

   1. Confirm that the timing mark (cutout) on the crankshaft pulley is aligned with the "0" timing mark of the timing chain cover assembly.

HINT:  Perform "Inspection After Repair" after replacing the camshaft timing gear assembly. Refer to INITIALIZATION [12/2023 - ]

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Timing Mark	*b	Mark Plate
   *c	Place on camshaft timing gear assembly	-	-

   1. 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.
   2. Install the chain sub-assembly to the camshaft timing gear assembly, and then set the camshaft timing gear assembly to the camshaft housing sub-assembly LH.

      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.
      • Be sure to install the camshaft timing gear assembly with the timing mark facing upward.

HINT:  Perform "Inspection After Repair" after replacing the camshaft timing exhaust gear assembly. Refer to INITIALIZATION [12/2023 - ]

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Timing Mark

   *b

   Mark Plate

   1. Align the mark plate (yellow) with the timing mark of the camshaft timing exhaust gear assembly as shown in the illustration and install the No. 2 chain sub-assembly to the camshaft timing exhaust gear assembly.
   2. Set the camshaft timing exhaust gear assembly to the camshaft housing sub-assembly LH.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. While lifting up the camshaft timing exhaust gear assembly, pass the No. 3 chain tensioner assembly through the No. 2 chain sub-assembly and set it in place.
      NOTE:

      Temporarily set the No. 3 chain tensioner assembly only, do not install the bolt.

HINT:  Perform "Inspection After Repair" after replacing the No. 3 camshaft sub-assembly. Refer to INITIALIZATION [12/2023 - ]

1. Courtesy 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
   *a	Pin Hole	*b	Straight Pin

   1. Clean the camshaft housing sub-assembly LH and No. 3 camshaft sub-assembly journals and apply engine oil to them.
   2. Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.
   3. Align the straight pin of the No. 3 camshaft sub-assembly and the pin hole of the camshaft timing gear assembly, and install the No. 3 camshaft sub-assembly to the camshaft timing gear assembly.
      NOTE:

      Be careful not to damage the contact surface of the camshaft timing gear assembly with the straight pin of the No. 3 camshaft sub-assembly.

   4. Check that there is no clearance between the camshaft timing gear assembly and No. 3 camshaft sub-assembly flange.

HINT:  Perform "Inspection After Repair" after replacing the No. 4 camshaft sub-assembly. Refer to INITIALIZATION [12/2023 - ]

1. Courtesy 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
   *a	Pin Hole	*b	Straight Pin

   1. Clean the camshaft housing sub-assembly LH and No. 4 camshaft sub-assembly journals and apply engine oil to them.
   2. Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.
   3. Align the straight pin of the No. 4 camshaft sub-assembly and the pin hole of the camshaft timing exhaust gear assembly, and install the No. 4 camshaft sub-assembly to the camshaft timing exhaust gear assembly.
      NOTE:

      Be careful not to damage the contact surface of the camshaft timing exhaust gear assembly with the straight pin of the No. 4 camshaft sub-assembly.

   4. Check that there is no clearance between the camshaft timing exhaust gear assembly and No. 4 camshaft sub-assembly flange.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	No. 3 Camshaft Bearing Cap	*2	No. 4 Camshaft Bearing Cap
   *a	Temporarily Bolt and Washer	-	-

   1. Clean the camshaft bearing caps and apply engine oil to them.
   2. Slide the camshaft timing gear assembly and camshaft timing exhaust gear assembly as shown in the illustration.

      HINT: 

      To ensure there is sufficient space for installing the No. 3 camshaft bearing cap and No. 4 camshaft bearing cap, slide the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

   3. Remove the temporarily bolts and washers (No. 3 camshaft bearing cap and No. 4 camshaft bearing cap side).
      NOTE:

      Do not remove any of the temporarily bolts and washers other than those on the No. 3 camshaft bearing cap and No. 4 camshaft bearing cap side.

   4. Temporarily set the No. 3 camshaft bearing cap and No. 4 camshaft bearing cap.
      NOTE:

      • Do not install the bolts of the No. 3 camshaft bearing cap and No. 4 camshaft bearing cap.
      • Do not install any camshaft bearing caps other than the No. 3 camshaft bearing cap and No. 4 camshaft bearing cap.
   5. Slide the camshaft timing gear assembly and camshaft timing exhaust gear assembly as shown in the illustration.
      NOTE:

      Securely insert the straight pins of the No. 3 camshaft sub-assembly and No. 4 camshaft sub-assembly into the pin holes of the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Hold	-	-
   	Turn	-	-

   1. Check that there is no clearance between the camshaft timing gear assembly and No. 3 camshaft sub-assembly flange.
   2. Apply engine oil to the areas of the camshaft timing gear bolt shown in the illustration.
   3. Use a wrench to hold the hexagonal portion of the No. 3 camshaft sub-assembly.
   4. Temporarily install the camshaft timing gear bolt.

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

      NOTE:

      • Installing the camshaft timing gear bolt while there is external force applied to the camshaft timing gear assembly could result in damage to the engine, so make sure that the camshaft bearing cap is not installed when temporarily installing the camshaft timing gear bolt.
      • Be careful not to damage the No. 3 camshaft sub-assembly, camshaft housing sub-assembly LH or spark plug tube with the wrench.
      • Make sure that the flange part of the camshaft timing gear bolt is directly contacting the camshaft timing gear assembly.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Hold	-	-
   	Turn	-	-

   1. Check that there is no clearance between the camshaft timing exhaust gear assembly and No. 4 camshaft sub-assembly flange.
   2. Apply engine oil to the areas of the camshaft timing gear bolt shown in the illustration.
   3. Use a wrench to hold the hexagonal portion of the No. 4 camshaft sub-assembly.
   4. Temporarily install the camshaft timing gear bolt.

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

      NOTE:

      • Installing the camshaft timing gear bolt while there is external force applied to the camshaft timing exhaust gear assembly could result in damage to the engine, so make sure that the camshaft bearing cap is not installed when temporarily installing the camshaft timing gear bolt.
      • Be careful not to damage the No. 4 camshaft sub-assembly, camshaft housing sub-assembly LH or spark plug tube with the wrench.
      • Make sure that the flange part of the camshaft timing gear bolt is directly contacting the camshaft timing exhaust gear assembly.

1. Fig 1: Camshaft Bearing Cap (For Bank 2) Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Temporarily Bolt and Washer	*b	Temporarily Bolt and Washer Removal
   *c	Part Installation	-	-
   	Bolt (A)		Bolt (B)

   1. Clean the camshaft bearing caps and apply engine oil to them.
   2. Check the marks and numbers on the camshaft bearing caps, and then remove the temporarily bolts and washers in the order shown in the illustration. Immediately after removing the temporarily bolts and washers in the location for a camshaft bearing cap, install the camshaft bearing cap with the bolts in the order shown in the illustration.

      Bolt (A) 

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

      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 temporarily bolts and washers into the cylinder head LH.
   3. Check the torque of each bolt again.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Hold	-	-
   	Turn	-	-

   1. Use a wrench to hold the hexagonal portion of the No. 3 camshaft sub-assembly.
   2. Tighten the camshaft timing gear bolt.

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

      NOTE:

      Be careful not to damage the No. 3 camshaft sub-assembly, camshaft housing sub-assembly LH or spark plug tube with the wrench.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Hold	-	-
   	Turn	-	-

   1. Use a wrench to hold the hexagonal portion of the No. 4 camshaft sub-assembly.
   2. Tighten the camshaft timing gear bolt.

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

      NOTE:

      Be careful not to damage the No. 4 camshaft sub-assembly, camshaft housing sub-assembly LH or spark plug tube with the wrench.

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Paint Mark

   -

   -

   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.

      HINT: 

      If the paint marks are not aligned, align them by turning the No. 3 camshaft sub-assembly slightly.

HINT:  Perform "Inspection After Repair" after replacing camshaft timing gear assembly. Refer to INITIALIZATION [12/2023 - ]

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Timing Mark	*b	Mark Plate
   *c	Place on camshaft timing gear assembly	-	-

   1. 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.
   2. Install the chain sub-assembly to the camshaft timing gear assembly, and then set the camshaft timing gear assembly to the camshaft housing sub-assembly RH.

      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.
      • Be sure to install the camshaft timing gear assembly with the timing mark facing upward.

HINT:  Perform "Inspection After Repair" after replacing the camshaft timing exhaust gear assembly. Refer to INITIALIZATION [12/2023 - ]

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Timing Mark

   *b

   Mark Plate

   1. Align the mark plate (yellow) with the timing mark of the camshaft timing exhaust gear assembly as shown in the illustration and install the No. 2 chain sub-assembly to the camshaft timing exhaust gear assembly.
   2. Set the camshaft timing exhaust gear assembly to the camshaft housing sub-assembly RH.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. While lifting up the camshaft timing exhaust gear assembly, pass the No. 2 chain tensioner assembly through the No. 2 chain sub-assembly and set it in place.
      NOTE:

      Temporarily set the No. 2 chain tensioner assembly only, do not install the bolt.

HINT:  Perform "Inspection After Repair" after replacing the camshaft. Refer to INITIALIZATION [12/2023 - ]

1. Courtesy 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
   *a	5 to 10°	*b	Pin Hole
   *c	Straight Pin	-	-

   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.

      HINT: 

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

   2. Clean the camshaft housing sub-assembly RH and camshaft journals and apply engine oil to them.
   3. Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.
   4. Align the straight pin of the camshaft and the pin hole of the camshaft timing gear assembly, and install the camshaft to the camshaft timing gear assembly.
      NOTE:

      Be careful not to damage the contact surface of the camshaft timing gear assembly with the straight pin of the camshaft.

   5. Check that there is no clearance between the camshaft timing gear assembly and camshaft flange.

HINT:  Perform "Inspection After Repair" after replacing the No. 2 camshaft. Refer to INITIALIZATION [12/2023 - ]

1. Courtesy 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
   *a	Pin Hole	*b	Straight Pin

   1. Clean the camshaft housing sub-assembly RH and No. 2 camshaft journals and apply engine oil to them.
   2. Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.
   3. Align the straight pin of the No. 2 camshaft and the pin hole of the camshaft timing exhaust gear assembly, and install the No. 2 camshaft to the camshaft timing exhaust gear assembly.
      NOTE:

      Be careful not to damage the contact surface of the camshaft timing exhaust gear assembly with the straight pin of the No. 2 camshaft.

   4. Check that there is no clearance between the camshaft timing exhaust gear assembly and No. 2 camshaft flange.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	No. 1 Camshaft Bearing Cap	*2	No. 2 Camshaft Bearing Cap
   *a	Temporarily Bolt and Washer	-	-

   1. Clean the camshaft bearing caps and apply engine oil to them.
   2. Slide the camshaft timing gear assembly and camshaft timing exhaust gear assembly as shown in the illustration.

      HINT: 

      To ensure there is sufficient space for installing the No. 1 camshaft bearing cap and No. 2 camshaft bearing cap, slide the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

   3. Remove the temporarily bolts and washers (No. 1 camshaft bearing and No. 2 camshaft bearing cap side).
      NOTE:

      Do not remove any of the temporarily bolts and washers other than those on the No. 1 camshaft bearing cap and No. 2 camshaft bearing cap side.

   4. Temporarily set the No. 1 camshaft bearing cap and No. 2 camshaft bearing cap.
      NOTE:

      • Do not install the bolts of the No. 1 camshaft bearing cap and No. 2 camshaft bearing cap.
      • Do not install any camshaft bearing caps other than the No. 1 camshaft bearing cap and No. 2 camshaft bearing cap.
   5. Slide the camshaft timing gear assembly and camshaft timing exhaust gear assembly as shown in the illustration.
      NOTE:

      Securely insert the straight pins of the camshaft and No. 2 camshaft into the pin holes of the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Hold	-	-
   	Turn	-	-

   1. Check that there is no clearance between the camshaft timing gear assembly and camshaft flange.
   2. Apply engine oil to the areas of the camshaft timing gear bolt shown in the illustration.
   3. Use a wrench to hold the hexagonal portion of the camshaft.
   4. Temporarily install the camshaft timing gear bolt.

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

      NOTE:

      • Installing the camshaft timing gear bolt while there is external force applied to the camshaft timing gear assembly could result in damage to the engine, so make sure that the camshaft bearing cap is not installed when temporarily installing the camshaft timing gear bolt.
      • Be careful not to damage the camshaft, camshaft housing sub-assembly RH or spark plug tube with the wrench.
      • Make sure that the flange part of the camshaft timing gear bolt is directly contacting the camshaft timing gear assembly.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Hold	-	-
   	Turn	-	-

   1. Check that there is no clearance between the camshaft timing exhaust gear assembly and No. 2 camshaft flange.
   2. Apply engine oil to the areas of the camshaft timing gear bolt shown in the illustration.
   3. Use a wrench to hold the hexagonal portion of the No. 2 camshaft.
   4. Temporarily install the camshaft timing gear bolt.

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

      NOTE:

      • Installing the camshaft timing gear bolt while there is external force applied to the camshaft timing exhaust gear assembly could result in damage to the engine, so make sure that the camshaft bearing cap is not installed when temporarily installing the camshaft timing gear bolt.
      • Be careful not to damage the No. 2 camshaft, camshaft housing sub-assembly RH or spark plug tube with the wrench.
      • Make sure that the flange part of the camshaft timing gear bolt is directly contacting the camshaft timing exhaust gear assembly.

1. Fig 2: Camshaft Bearing Cap (For Bank 1) Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Temporarily Bolt and Washer	*b	Temporarily Bolt and Washer Removal
   *c	Part Installation	-	-
   	Bolt (A)		Bolt (B)
   	Bolt (C)	-	-

   1. Clean the camshaft bearing caps and apply engine oil to them.
   2. Check the marks and numbers on the camshaft bearing caps, and then remove the temporarily bolts and washers in the order shown in the illustration. Immediately after removing the temporarily bolts and washers in the location for a camshaft bearing cap, install the camshaft bearing cap with the bolts in the order shown in the illustration.

      Bolt (A) 

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

      Bolt (B), (C) 

      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 temporarily bolts and washers into the cylinder head sub-assembly.
   3. Check the torque of each bolt again.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Hold	-	-
   	Turn	-	-

   1. Use a wrench to hold the hexagonal portion of the camshaft.
   2. Tighten the camshaft timing gear bolt.

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

      NOTE:

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Hold	-	-
   	Turn	-	-

   1. Use a wrench to hold the hexagonal portion of the No. 2 camshaft.
   2. Tighten the camshaft timing gear bolt.

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

      NOTE:

      Be careful not to damage the No. 2 camshaft, camshaft housing sub-assembly RH or spark plug tube with the wrench.

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Paint Mark

   -

   -

   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.

      HINT: 

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Stopper Plate

   *b

   Plunger

   1. Turn the crankshaft counterclockwise 30° past the "0" timing mark, and then turn it clockwise to align the cutout with the "0" timing mark.
   2. Turn the crankshaft slightly to eliminate the slack in the chain sub-assembly.

      HINT: 

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

   3. Turn the stopper plate clockwise to release the lock, and push the plunger deep into the No. 1 chain tensioner assembly.
   4. Turn the stopper plate counterclockwise to set the lock, and insert a 1.0 mm (0.0394 in.) diameter pin into the hole of the stopper plate.
   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 1.0 mm (0.0394 in.) diameter pin from the No. 1 chain tensioner assembly.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Timing Mark

   *b

   Viewpoint

   1. Check that each camshaft timing mark is positioned as shown in the illustration. If the valve timing is misaligned, reinstall the chain sub-assembly.
      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 and each camshaft timing exhaust gear assembly.
      • If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.

      HINT: 

      For the camshaft or No. 3 camshaft sub-assembly:

      Be sure to check mark (A) at the point where the marks (B) and (C) are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      *a	Timing Mark

   2. Turn the crankshaft 2 revolutions, set the No. 1 cylinder to TDC (compression) and check the timing marks again.

Refer to PROCEDURE - Step 47

Refer to PROCEDURE - Step 9

Refer to PROCEDURE - Step 19

Refer to PROCEDURE - Step 20

Refer to PROCEDURE - Step 25

Refer to PROCEDURE - Step 28

Refer to INSTALLATION [12/2023 - ]