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Engine Mechanical (Hybrid): Camshaft: Installation

  1. INSTALL CAMSHAFT SUB GEAR 
    1. Clamp the camshaft in a vise on the hexagonal lobe.
      NOTE: Do not damage the camshaft.
      Fig 1: Clamping Camshaft In A Vise On Hexagonal Lobe
      G05200370Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the camshaft gear bolt washer and the camshaft sub-gear.

      HINT:

      Attach the pins on the gears to the gear bolt washer ends.

    3. Install the wave washer.
      Fig 2: Identifying Camshaft Gear Bolt Washer And Camshaft Sub Gear
      G05200371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using snap ring pliers, install the snap ring.
      Fig 3: Installing Snap Ring
      G05200368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST, align the holes of the camshaft main gear and sub-gear by turning camshaft sub-gear counterclockwise, and temporarily install a service bolt.

      SST 09960-10010 (09962-01000, 09963-00500) 

    6. Align the gear teeth of the main gear and sub-gear, and tighten the service bolt.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

      NOTE: Do not damage the camshaft journals.
      Fig 4: Aligning Gear Teeth Of Main Gear And Sub Gear
      G05129555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      When installing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by installing the service bolt.

  2. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Align the alignment pin with the groove and install the VVT-i on the camshaft.
      NOTE: Install it with the lock-pin engaged and locked at the most retard angle position.
    2. Apply engine oil to the nut, the mounting surface of VVT-i and the screw threads.
      Fig 5: Aligning Alignment Pin With Alignment Pin Groove
      G05200374Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be sure to apply oil, otherwise the specified torque cannot be obtained.
      • A new nut must be used when replacing the VVT-i unit.
    3. Using a 46 mm socket wrench, install and tighten a lock nut by turning it counterclockwise.

      Torque: 150 N*m (1,530 kgf*cm, 111 ft.*lbf) 

      NOTE:
      • The lock nut has left-hand threads.
      • Never use any tool other than the socket wrench. Other tools will deform the cam angle rotor.
        Fig 6: Installing And Tightening Lock Nut By Turning Counterclockwise
        G05200375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO.4 CAMSHAFT SUB-ASSEMBLY 
    NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.
    1. Apply new engine oil to the thrust portion and journal of the camshaft.
    2. Place the No.4 camshaft at 90° angle of the timing mark (1-dot mark) on the cylinder head.
    3. Apply MP grease to a new oil seal lip.
      Fig 7: Identifying Timing Mark On Cylinder Head
      G05200376Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the oil seal to the camshaft.
      NOTE:
      • Do not turn over the oil seal lip.
      • Insert the oil seal until it stops.
    5. Remove any old packing material from the contact surface.
      Fig 8: Installing Oil Seal To Camshaft
      G05200377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Apply seal packing to the No.1 bearing cap as shown in the illustration.

      Seal packing: 

      Part No.08826-00080 or equivalent 

      NOTE:
      • Install the No.1 bearing cap within 5 minutes after applying seal packing.
      • Do not expose the seal to engine oil within 2 hours after installing.
        Fig 9: Applying Seal Packing To No. 1 Bearing Cap
        G05129560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the 5 bearing caps in their proper locations.
    8. Apply a light coat of engine oil to the threads of the bearing cap bolts.
      Fig 10: Applying Light Coat Of Engine Oil On Threads Of Bearing Cap Bolts
      G05200379Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Using several steps, install and tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.

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

      Fig 11: Identifying Bearing Cap Bolts Tightening Sequence
      G05129570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL N0.3 CAMSHAFT SUB-ASSEMBLY 
    NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.
    1. Apply new engine oil to the thrust portion and journal of the camshaft.
    2. Align the timing marks (1 -dot mark) of the camshaft drive gear with the mark on the driven gear.
    3. Place the camshaft on the cylinder head.
      Fig 12: Aligning Timing Marks Of Camshaft Drive Gear With Mark On Driven Gears
      G05200381Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the 5 bearing caps in their proper locations.
    5. Apply a light coat of engine oil to the threads of the bearing cap bolts.
      Fig 13: Applying Light Coat Of Engine Oil On Threads Of Bearing Cap Bolts
      G05200382Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using several steps, install and tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.

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

    7. Remove the service bolt.
  5. INSTALL NO.2 CAMSHAFT 
    NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.
    Fig 14: Identifying Bearing Cap Bolts Tightening Sequence
    G05129573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Apply new engine oil to the thrust portion and journal of the camshaft.
    2. Place the No.2 camshaft at 90° angle of the timing mark (2-dot mark) on the cylinder head.
    3. Apply MP grease to a new oil seal lip.
      Fig 15: Identifying Timing Mark On Cylinder Head
      G05200384Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the oil seal to the camshaft.
      NOTE:
      • Do not turn over the oil seal lip.
      • Insert the oil seal until it stops.
    5. Remove any old packing material from the contact surface.
      Fig 16: Installing Oil Seal To Camshaft
      G05200385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Apply seal packing to the No. 1 bearing cap as shown in the illustration.

      Seal packing: 

      Part No.08826-00080 or equivalent 

      NOTE:
      • Install the No.1 bearing cap within 5 minutes after applying seal packing.
      • Do not expose the seal to engine oil within 2 hours after installing.
        Fig 17: Identifying Seal Packing To Bearing Cap
        G05129560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the 5 bearing caps in their proper locations.
    8. Apply a light coat of engine oil to the threads of the bearing cap bolts.
      Fig 18: Applying Light Coat Of Engine Oil On Threads Of Bearing Cap
      G05200387Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.

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

      Fig 19: Identifying Bearing Cap Bolts Tightening Sequence
      G05129562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL CAMSHAFT 
    NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.
    1. Apply new engine oil to the thrust portion and journal of the camshaft.
    2. Align the timing marks (2-dot mark) of the camshaft drive gear with the mark on the driven gear.
    3. Place the camshaft on the cylinder head.
      Fig 20: Aligning Camshaft Drive And Driven Gear'S Timing Marks
      G05129563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the 5 bearing caps in their proper locations.
    5. Apply a light coat of engine oil to the threads of the bearing cap bolts.
      Fig 21: Applying Light Coat Of Engine Oil On Threads Of Bearing Cap Bolts
      G05200390Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.

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

    7. Remove the service bolt.
  7. INSTALL TIMING BELT NO.3 COVER 
    1. Visually check for cracks and breaks on the gasket of the timing belt cover.

      HINT:

      If a trace of water is found in the visual check, repair it with seal packing when the crack length is within 2 to 3 cm (0.79 to 1.18 in.). Replace the gasket when the crack length is 3 to 4 cm (1.18 to 1.57 in.) and more.

      Fig 22: Identifying Bearing Cap Bolts Tightening Sequence
      G05200391Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. If the timing belt cover gasket is needed to repair, follow the procedure below.
      1. Repair the cracks and breaks by applying the seal packing to the damaged area.

        Seal packing: 

        Part No.08826-00080 or equivalent 

        NOTE: When applying the seal packing, apply it as wide and high as possible to fill the surface area of the gasket.
        Fig 23: Applying Seal Packing To Damaged Area
        G05129577Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. If the timing belt cover gasket is needed to replace, follow the procedure below.
      1. Using a screwdriver and gasket scraper, remove the remaining gasket.
        NOTE: Do not damage the timing belt cover.
      2. Remove the backing paper from a new gasket, and affix the gasket along the groove of the timing belt cover as shown in the illustration.
        NOTE:
        • Affix the gasket in the center of the groove.
        • At the corners, try to keep the gasket thickness uniform.

        HINT:

        Gasket length

        GASKET LENGTH SPECIFICATION

        Gasket D E F G
        Length 335 mm (13.19 in.) 180 mm (7.09 in.) 133 mm (5.24 in.) 72 mm (2.83 in.)
      3. If there is a gap on the joint of the gasket, apply seal packing to close the gap.
        Fig 24: Affixing Gasket Along Groove Of Timing Belt Cover
        G05129578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Seal packing: 

        Part No.08826-00080 or equivalent 

        NOTE: When applying the seal packing, apply it as wide and high as possible to fill the surface area of the gasket.
    4. Install the timing belt cover No.3 with the 6 bolts.

      Torque: 8.5 N*m (87 kgf*cm, 76 in.*lbf) 

      Fig 25: Locating Timing Belt Cover No 3 With Bolts
      G05200355Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL CAMSHAFT TIMING PULLEY 
    1. Paying attention to the direction of the belt guide, install the camshaft timing pulley and tighten the bolt temporally.

      HINT:

      • Face the belt guide of the RH timing pulley toward front of the engine.
      • Face the belt guide of the LH timing pulley toward rear of the engine.
        Fig 26: Identifying Camshaft Timing Pulley
        G05129579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, tighten the RH pulley bolt.
      Fig 27: Tightening RH Pulley Bolt
      G05200396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09960-10010 (09962-01000, 09963-01000), 09249-63010 

      Torque: 125 N*m (1,275 kgf*cm, 92 ft.*lbf) 

      NOTE: The torque indicated above is for using SST without any extension tool. If extension tools are used, find the reading of the torque wrench by the formula (See REPAIR INSTRUCTION ).

      Extended length: 

      SST (09249-63010) 150 mm (5.91 in.) 

    3. Using SST, tighten the LH pulley bolt.
      Fig 28: Tightening LH Pulley Bolt
      G05200397Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09960-10010 (09962-01000, 09963-01000) 

      Torque: 125 N*m (1,275 kgf*cm, 92 ft.*lbf) 

  9. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO.2 
    1. Install the timing belt idler sub-assembly No.2.

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

  10. INSPECT TIMING BELT (See  INSTALLATION   ) 
  11. INSTALL TIMING BELT (See  INSTALLATION   ) 
  12. INSTALL CHAIN TENSIONER ASSEMBLY NO.1 (See  INSTALLATION   ) 
  13. INSTALL TIMING BELT GUIDE NO.2 (See  INSTALLATION   ) 
  14. INSTALL ENGINE MOUNTING BRACKET RH (See  INSTALLATION   ) 
  15. INSTALL TIMING BELT NO.2 COVER (See  INSTALLATION   ) 
  16. INSTALL TIMING BELT NO.1 COVER (See  INSTALLATION   ) 
  17. INSTALL CRANKSHAFT PULLEY (See  INSTALLATION   ) 
  18. INSTALL ENGINE MOUNTING STAY NO.2 RH (See  INSTALLATION   ) 
  19. INSTALL ENGINE MOVING CONTROL ROD (See  INSTALLATION   ) 
  20. INSTALL AIR CLEANER BRACKET (See  INSTALLATION   ) 
  21. INSTALL RESERVOIR BRACKET (See  INSTALLATION   ) 
  22. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY (See  INSTALLATION   ) 
  23. INSPECT VALVE CLEARANCE (See  ADJUSTMENT   ) 
  24. ADJUST VALVE CLEARANCE (See  ADJUSTMENT   ) 
  25. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (See  ADJUSTMENT   ) 
  26. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH (See  ADJUSTMENT   ) 
  27. INSTALL IGNITION COIL ASSEMBLY 

    Torque: 8.0 N*m (80 kgf*cm, 71 in.*lbf) 

  28. CONNECT RADIATOR HOSE INLET 
  29. INSTALL INTAKE AIR SURGE TANK  (See INSTALLATION )
  30. INSTALL EMISSION CONTROL VALVE SET  (See INSTALLATION )
  31. INSTALL AIR CLEANER CASE W/ RESONATOR  (See INSTALLATION )
  32. INSTALL AIR CLEANER CAP W/ INLET (See  INSTALLATION   ) 
  33. INSTALL FRONT SUSPENSION BRACE SUB-ASSEMBLY UPPER CENTER (See  INSTALLATION   ) 
  34. INSTALL BATTERY CARRIER SUB-ASSEMBLY (See  INSTALLATION   ) 
  35. INSTALL BATTERY (See  INSTALLATION   ) 
  36. INSTALL FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER (See  INSTALLATION   ) 
  37. INSTALL FRONT FENDER APRON SEAL RH (See  INSTALLATION   ) 
  38. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (See  INSTALLATION   ) 
  39. INSTALL ENGINE UNDER COVER NO.1 (See  INSTALLATION   ) 
  40. INSTALL FRONT WHEEL RH 
  41. ADD ENGINE OIL 
  42. ADD COOLANT  (See COOLANT )
  43. INSPECT FOR ENGINE COOLANT LEAK  (See COOLING SYSTEM )
  44. INSPECT FOR OIL LEAK 
  45. INSPECT IGNITION TIMING (See  ON-VEHICLE INSPECTION   ) 
  46. INSPECT IDLE SPEED (See  ON-VEHICLE INSPECTION   ) 
  47. PERFORM INITIALIZATION 
    1. Some system need initialization when reconnecting the cable from the battery terminal. (See INITIALIZATION )
  48. INSTALL ENGINE ROOM SIDE LH COVER NO.2 (See  INSTALLATION   ) 
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