LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2009 >> Highlander Limited, FWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (2GR-FE) >> CAMSHAFT (for Bank 1) >> Installation

CAMSHAFT (for Bank 1): Installation

Fig 1: Identifying Flange Bolt And Straight Pin
G06112357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. INSTALL CAMSHAFT BEARING CAP 
    1. Apply engine oil to the camshaft journals, camshaft housing sub-assembly RH and camshaft bearing caps.
    2. Install the camshaft and No. 2 camshaft to the camshaft housing sub-assembly RH.
    3. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.
      Fig 2: Identifying Marks And Numbers On Camshaft Bearing Caps
      G04974792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Temporarily tighten the 8 bearing cap bolts in the order shown in the illustration.

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

      Fig 3: Tightening Bolts In Sequence
      G04974793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH 
    1. Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.
      Fig 4: Applying Engine Oil To Lash Adjuster Tips And Valve Stem Cap Ends
      G04974791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply seal packing in a continuous line as shown in the illustration.

      Seal packing: 

      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent 

      Seal diameter: 

      3.5 to 4.5 mm (0.138 to 0.177 in.) 

      NOTE:
      • Remove any oil from the contact surface.
      • Install the camshaft housing sub-assembly RH within 3 minutes.
      • Do not start the engine for at least 2 hours after installing.
        Fig 5: Identifying Seal Packing
        G05136857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the camshaft housing sub-assembly RH and tighten the 12 bolts in the order shown in the illustration.

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

      NOTE:
      • When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts 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.
      • If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
      • If the camshaft housing sub-assembly is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
        Fig 6: Identifying Camshaft Housing Tighten Bolts Sequence
        G04974796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten the 8 bolts in the order shown in the illustration.

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

      Fig 7: Identifying Camshaft Housing Tighten Bolts Sequence
      G04974797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY 
    1. Install the No. 2 chain tensioner assembly with the bolt.

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

    2. While pushing in the tensioner, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to fix it.
      Fig 8: Installing No 2 Chain Tensioner
      G04974804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) 
    1. Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.
    2. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.
    3. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear assembly LH with the No. 2 chain subassembly installed.
      Fig 9: Identifying Camshaft Timing Gear Timing Mark
      G05136867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST to hold the hexagonal portion of each camshaft, tighten the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly LH.

      SST 09922-10010 

      Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) 

    5. Remove the pin from the No. 2 chain tensioner assembly.
      Fig 10: Tightening Flange Bolts Of Camshaft Timing Gear Assembly
      G06112340Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL IDLE SPROCKET ASSEMBLY  (See REASSEMBLY  )
  6. INSTALL CHAIN SUB-ASSEMBLY  (See REASSEMBLY  )
  7. INSTALL CHAIN TENSIONER SLIPPER  (See REASSEMBLY  )
  8. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY  (See REASSEMBLY  )
  9. INSTALL TIMING CHAIN CASE OIL SEAL  (See REASSEMBLY  )
  10. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY  (See REASSEMBLY  )
  11. INSTALL OIL PAN SUB-ASSEMBLY  (See REASSEMBLY  )
  12. INSTALL OIL STRAINER SUB-ASSEMBLY  (See REASSEMBLY  )
  13. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY  (See REASSEMBLY  )
  14. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)  (See REASSEMBLY  )
  15. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)  (See REASSEMBLY  )
  16. INSTALL WATER OUTLET  (See REASSEMBLY  )
  17. INSTALL WATER INLET HOUSING  (See REASSEMBLY  )
  18. INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler)  (See REASSEMBLY  )
  19. INSTALL OIL COOLER ASSEMBLY (w/ Oil Cooler)  (See REASSEMBLY  )
  20. INSTALL CRANKSHAFT PULLEY  (See REASSEMBLY  )
  21. INSTALL OIL PIPE  (See REASSEMBLY  )
  22. INSTALL NO. 1 OIL PIPE  (See REASSEMBLY  )
  23. INSTALL CRANKSHAFT POSITION SENSOR  (See REASSEMBLY  )
  24. INSTALL KNOCK CONTROL SENSOR  (See INSPECTION )
  25. INSTALL KNOCK CONTROL SENSOR WIRE  (See INSTALLATION  )
  26. INSTALL NO. 1 VACUUM SWITCHING VALVE  (See INSTALLATION  )
  27. INSTALL RADIO SETTING CONDENSER  (See INSTALLATION  )
  28. INSTALL NO. 1 ENGINE FRONT MOUNTING BRACKET LH 
    1. Install the No. 1 front engine mounting bracket LH with the 6 bolts.

      Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 

      NOTE:
      • Install the water inlet and mounting bracket within 15 minutes after installing the chain cover.
      • Do not start the engine for at least 2 hours after installation.
        Fig 11: Locating Engine Mounting Bracket Front And Bolts
        G04974578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY  (See INSTALLATION  )
  30. INSTALL NO. 2 TIMING GEAR COVER  (See INSTALLATION  )
  31. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY  (See INSTALLATION  )
  32. INSTALL GENERATOR ASSEMBLY  (See INSTALLATION )
  33. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET  (See INSTALLATION  )
  34. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH  (See INSTALLATION  )
  35. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR  (See INSTALLATION  )
  36. INSTALL NO. 2 MANIFOLD STAY  (See INSTALLATION  )
  37. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE  (See INSTALLATION  )
  38. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH  (See INSTALLATION  )
  39. INSTALL INTAKE MANIFOLD  (See INSTALLATION  )
  40. INSTALL NO. 2 ENGINE MOUNTING STAY RH  (See INSTALLATION  )
  41. INSTALL IGNITION COIL ASSEMBLY  (See INSTALLATION )
  42. REMOVE ENGINE STAND 
  43. INSTALL ENGINE ASSEMBLY 

    HINT:

    See INSTALLATION  .

scientia non olet · About LEMON Manuals