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Engine Mechanical (2AZ-FE): Camshaft: Installation

  1. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Put the camshaft timing gear and camshaft together with the straight pin and key groove misaligned, as shown in the illustration.
      Fig 1: Aligning Straight Pin And Key Groove
      G06008243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Turn the camshaft timing gear as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.
      NOTE: Be sure not to turn the camshaft timing gear to the retard direction (clockwise).
      Fig 2: Turning Camshaft Timing Gear
      G05387052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check that there is no clearance between the timing gear and camshaft flange.
      Fig 3: Identifying Clearance Between Timing Gear And Camshaft Flange
      G06040911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten the flange bolt with the camshaft timing gear assembly secured in place.

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

      Fig 4: Locating Flange Bolt
      G05387054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Check that the camshaft timing gear assembly can move to the retard direction (clockwise) and is locked in the most retarded position.
  2. INSTALL CAMSHAFT 
    1. Apply a light coat of engine oil to the journal portion of the camshaft.
      Fig 5: Checking Camshaft Timing Gear Assembly
      G05387055Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the timing chain onto the camshaft timing gear with the paint mark aligned with the timing mark on the camshaft timing gear as shown in the illustration.
      Fig 6: Identifying Timing Mark On Camshaft Timing Gear
      G04974024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps into the cylinder head.
    4. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
      Fig 7: Identifying Bearing Caps Illustration Sequence
      G04973940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.

      Torque: No. 1 bearing 

      30 N*m (301 kgf*cm, 22 ft.*lbf) 

      No. 3 bearing 

      9.0 N*m (92 kgf*cm, 80 in.*lbf) 

      Fig 8: Identifying Bearing Cap Bolts Tightening Sequence
      G04973941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 2 CAMSHAFT 
    1. Apply a light coat of engine oil to the journal portion of the No. 2 camshaft.
    2. Put the No. 2 camshaft on the cylinder head with the paint mark on the chain aligned with the timing mark on the camshaft timing sprocket.
      Fig 9: Identifying Timing Mark On Camshaft Timing Sprocket
      G05387059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. While holding the No. 2 camshaft by hand, temporarily tighten the camshaft timing sprocket set bolt.
      Fig 10: Tightening Camshaft Timing Sprocket Set Bolt
      G05387060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head.
    5. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
      Fig 11: Identifying Bearing Caps Illustration Sequence
      G04973944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.

      Torque: No. 2 bearing 

      30 N*m (301 kgf*cm, 22 ft.*lbf) 

      No. 3 bearing 

      9.0 N*m (92 kgf*cm, 80 in.*lbf) 

      Fig 12: Identifying Bearing Cap Bolts Tightening Sequence
      G04973945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. While holding the camshaft with a wrench, tighten the camshaft timing sprocket set bolt.

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

      NOTE: Be careful not to damage the valve lifter.
      Fig 13: Tightening Camshaft Timing Sprocket Set Bolt
      G05387063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Check that the paint marks on the chain are aligned with the timing marks on the camshaft timing gear and camshaft timing sprocket. Also, check that the crankshaft pulley groove is aligned with the timing mark "0" on the timing mark chain cover.
    Fig 14: Aligning Timing Marks On Camshaft Timing Gear And Camshaft Timing Sprocket
    G04973947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Release the ratchet pawl, then fully push in the plunger and set the hook to the pin so that the plunger is in the position shown in the illustration.
      Fig 15: Releasing Ratchet Pawl
      G04973997Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new gasket and the chain tensioner with the 2 nuts.

      Torque: 9.0 N*m (92 kgf* cm, 80 in.*lbf) 

      NOTE: When installing the chain tensioner, set the hook again if the hook releases the plunger.
      Fig 16: Identifying Gasket And Chain Tensioner With Nuts
      G05387066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Turn the crankshaft counterclockwise, then disconnect the hook from the pin.
      Fig 17: Disconnecting Hook From Pin
      G04973999Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Turn the crankshaft clockwise, then check that the plunger is extended.
      Fig 18: Checking Plunger Extension
      G06040926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. SET NO. 1 CYLINDER TO TDC/COMPRESSION  (See REMOVAL )
  6. CHECK VALVE CLEARANCE  (See VALVE CLEARANCE )
  7. ADJUST VALVE CLEARANCE  (See VALVE CLEARANCE )
  8. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Remove any old packing material from the contact surface.
    2. Apply seal packing to the 2 locations shown in the illustration.

      Seal packing: 

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

      NOTE:
      • Remove any oil from the contact surface.
      • Install the oil pan within 3 minutes of applying seal packing.
      • Do not add engine oil for at least 2 hours after installing the oil pan.
      Fig 19: Identifying Seal Packing Applying Area
      G04974001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the cylinder head cover gasket and sub-assembly with the 8 bolts and 2 nuts.

      Torque: Bolt A 

      11 N*m (112 kgf*cm, 8 ft.*lbf) 

      Bolt B 

      14 N*m (143 kgf*cm, 10 ft.*lbf) 

      Nut 

      11 N*m (112 kgf*cm, 8 ft.*lbf) 

      Fig 20: Locating Cylinder Head Cover Bolts
      G05387070Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the 2 engine wire harness brackets with the 2 bolts.

      Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 

      Fig 21: Locating Wire Harness Brackets Bolts
      G04974003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the 2 ventilation hoses to the cylinder head cover.
      Fig 22: Locating Ventilation Hoses
      G05387037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL SPARK PLUG  (See INSTALLATION )
  10. INSTALL IGNITION COIL ASSEMBLY  (See INSTALLATION )
  11. INSPECT FOR OIL LEAK 
  12. INSPECT IGNITION TIMING  (See ENGINE )
  13. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY  (See INSTALLATION )
  14. INSTALL ENGINE UNDER COVER RH 
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