Section 4 (Engine Mechanical (1AR-FE)): Camshaft: Installation

HINT:

When installing the camshaft timing gear, release the lock pin and set the camshaft timing gear to the advanced position before installation.

1. Check the camshaft timing gear position.
   NOTE: If the camshaft timing gear is set to the advanced position, do not let the camshaft timing gear rotate clockwise during installation. If the camshaft timing gear rotates to the retarded position, release the lock pin and set the camshaft timing gear to the advanced position.
   Fig 1: Identifying Camshaft Timing Gear Advanced Position And Retarded Position

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2. Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear.
   Fig 2: Identifying Knock Pin And Pin Hole

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3. Check that there is no clearance between the camshaft timing gear and camshaft flange.
4. Hold the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear by hand.
   NOTE: Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.
   Fig 3: Identifying Clearance Between Camshaft Timing Gear And Camshaft Flange

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5. Release the lock pin.
   1. Clean the camshaft journal with a non-residue solvent.
   2. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

      HINT:

      There are 4 oil paths in the grooves of the camshaft. Plug 3 of the paths with pieces of rubber.

   3. Open a hole at port A shown in the illustration.
      Fig 4: Covering Oil Paths Of Cam Journal With Vinyl Tape

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   4. While applying approximately 200 kPa (2.0 kgf/cm² , 29 psi) of air pressure to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).
      CAUTION: Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.
      NOTE: Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.
      Fig 5: Applying Air Pressure To Oil Path

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      HINT:

      • The camshaft timing gear assembly may be turned in the advance direction without applying any force.
      • If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.
   5. Remove the vinyl tape and rubber pieces from the camshaft.
6. Remove the bolt and camshaft timing gear.

1. Inspect the valve lash adjuster before installing it (See INSPECTION ).
2. Install the 16 lash adjusters to the cylinder head.

1. Apply engine oil to the lash adjuster tips and valve stem caps.
2. Install the 16 valve rocker arms as shown in the illustration.

1. Clean the camshaft journals, camshaft housing and bearing caps.
2. Apply a light coat of engine oil to the camshaft journal, camshaft housing and bearing caps.
3. Install the No. 1 and No. 2 camshafts to the camshaft housing.

1. Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.
   Fig 7: Identifying Marks And Numbers On Camshaft Bearing Caps

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2. Install the 11 bolts in the order shown in the illustration.

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

   NOTE: Make sure that the camshaft rotates smoothly after installing the bearing caps.

Fig 8: Identifying Camshaft Bearing Caps Bolts Tightening Sequence

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1. Check that the valve rocker arms are installed as shown in the illustration.
   Fig 9: Identifying Valve Rocker Arms Position

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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 

   Standard seal diameter: 

   3.0 to 4.0 mm (0.118 to 0.157 in.) 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the camshaft housing within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
   Fig 10: Identifying Seal Diameter

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3. Position the knock pin of the No. 1 and No. 2 camshafts as shown in the illustration.
   Fig 11: Identifying No. 1 And No. 2 Camshafts Knock Pin Positioning

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4. Install the camshaft housing, and then install the 20 bolts in the order shown in the illustration.

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

   NOTE:

   • Do not apply oil for at least 4 hours after the installation.
   • Do not start the engine for at least 4 hours after the installation.
   • Thoroughly wipe clean any seal packing.

Fig 12: Identifying Camshaft Housing Bolts Tightening Sequence

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1. Check the camshaft timing gear position. If the camshaft timing gear is not set to the advanced position, release the lock pin and reset the camshaft timing gear (Refer to the "SET CAMSHAFT TIMING GEAR ASSEMBLY" procedures).
   Fig 13: Identifying Camshaft Timing Gear Installation Position

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2. Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear.
   Fig 14: Identifying Knock Pin And Pin Hole

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3. Check that there is no clearance between the camshaft timing gear and camshaft flange.
   Fig 15: Identifying Clearance Between Camshaft Timing Gear And Camshaft Flange

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4. Using a wrench to hold the hexagonal portion of the No. 1 camshaft, install the bolt.

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

   NOTE:

   • Be careful not to damage the cylinder head or spark plug tube with the wrench.
   • Do not disassemble the camshaft timing gear.

Fig 16: Installing No. 1 Camshaft Bolt

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1. Align and attach the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear.
   Fig 17: Identifying No. 2 Camshaft Knock Pin And Camshaft Timing Exhaust Gear Pin Hole

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2. Check that there is no clearance between the camshaft timing exhaust gear and camshaft flange.
   Fig 18: Identifying Clearance Between Camshaft Timing Exhaust Gear And Camshaft Flange

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3. Using a wrench to hold the hexagonal portion of the No. 2 camshaft, install the bolt.

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

   NOTE:

   • Be careful not to damage the cylinder head or spark plug tube with the wrench.
   • Do not disassemble the camshaft timing exhaust gear.

Fig 19: Installing No. 2 Camshaft Bolt

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1. Add 50 cc (3.1 cu. in) of engine oil into the oil hole shown in the illustration.

Fig 20: Adding Of Engine Oil Into Oil Hole

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1. Temporarily install the crankshaft pulley bolt.
2. Rotate the crankshaft 40° counterclockwise to position the crankshaft pulley key as shown in the illustration.
   Fig 21: Positioning Of Crankshaft Pulley Key

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3. Check that the timing marks of the camshaft timing gears are as shown in the illustration.

   HINT:

   "A" is not a timing mark.

   Fig 22: Identifying Timing Marks Of Camshaft Timing Gears

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1. Install the chain vibration damper with the 2 bolts.

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

1. Place the chain onto the camshaft timing gears and crankshaft timing sprocket.

   HINT:

   • Make sure the mark plate of the chain faces away from the engine.
   • It is not necessary to install the chain to the teeth of the gears and sprocket.
   Fig 23: Locating Chain Vibration Damper Bolts

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2. Align the mark plate (yellow or gold) of the chain with the timing mark of the camshaft timing exhaust gear and install the chain to the camshaft timing exhaust gear.
   Fig 24: Identifying Mark Plate (Yellow Or Gold) Of Chain And Timing Mark Of Camshaft Timing Exhaust Gear

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3. Align the mark plate (pink or gold) of the chain with the timing mark of the crankshaft timing sprocket and install the chain to the crankshaft timing sprocket.
   Fig 25: Identifying Mark Plate (Pink Or Gold) Of Chain And Timing Mark Of Crankshaft Timing Sprocket

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4. Tie a string above the crankshaft timing sprocket so that the chain is secure.
   Fig 26: Tying String Above Crankshaft Timing Sprocket

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5. Using the hexagonal portion of the intake camshaft, rotate the intake camshaft counterclockwise with a wrench, align the timing mark of the camshaft timing gear with the mark plate (yellow or gold) of the chain and install the chain to the camshaft timing gear.

   HINT:

   Hold the intake camshaft in place with a wrench until the chain tensioner is installed.

   Fig 27: Aligning Timing Mark Of Camshaft Timing Gear With Mark Plate (Yellow Or Gold) Of Chain

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6. Remove the string above the crankshaft timing sprocket, rotate the crankshaft clockwise, and loosen the chain so that the chain tensioner slipper can be installed.

Fig 28: Loosening Chain

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1. Install the chain tensioner slipper with the bolt.

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

Fig 29: Locating Chain Tensioner Slipper Bolt

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1. Install a new gasket and the chain tensioner with the 2 bolts.

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

2. Remove the pin from the stopper plate.

Fig 30: Locating Chain Tensioner Bolts

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1. Install the timing chain guide with the bolt

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

Fig 31: Locating Timing Chain Guide Bolt

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1. Temporarily install the crankshaft pulley bolt.
   Fig 32: Identifying Timing Marks On Crankshaft Timing Gear And Camshaft Timing Gears

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2. Rotate the crankshaft clockwise, and check that the timing marks on the crankshaft timing sprocket and camshaft timing gears are as shown in the illustration.

   HINT:

   "A" is not a timing mark.

3. Remove the crankshaft pulley bolt.

1. Install the timing chain cover (See INSTALLATION ).