CAMSHAFT > INSTALLATION

for Preparation Click here



1. INSTALL CAMSHAFT


    A198508E02

  1. Turn the crankshaft to set the key in the 70° BTDC position.
    Text in Illustration 
    *1
    		TDC Mark
    *2
    		Key

  1. Apply engine oil to the camshaft journal portion and cam portion.



    A198511E01

  1. Examine the front marks and numbers and check that the sequence is as shown in the illustration. Then, temporarily tighten the camshaft with the camshaft bearing caps and bolts.

    NOTICE:
    Do not tilt the valve rocker arm when installing the camshaft onto the cylinder head.



    A200011E01

  1. Using several steps, temporarily tighten the bolts in the sequence shown in the illustration, and then tighten the bolts to the specified torque.

    Torque:
    19 N*m{ 194 kgf*cm , 14 ft.*lbf }



2. INSTALL CHAIN SUB-ASSEMBLY


    G035839E02

  1. Turn the camshaft to set the straight pin in the position shown in the illustration.
    Text in Illustration 
    *1
    		Straight Pin



    A198509E02

  1. Turn the crankshaft to set the key in the position shown in the illustration.
    Text in Illustration 
    *1
    		TDC Mark
    *2
    		Key



    A198520E02

  1. Align the chain's 2 orange mark plates with the timing mark on the camshaft timing sprocket, and the yellow mark plate with the timing mark on the crankshaft timing sprocket.
    Text in Illustration 
    *1
    		Timing Mark
    *2
    		Orange Mark Plate
    *3
    		Yellow Mark Plate



    A198521E02

  1. Install the chain, camshaft timing sprocket and crankshaft sprocket together onto the engine.
    Text in Illustration 
    *1
    		Timing Mark
    *2
    		Orange Mark Plate
    *3
    		Yellow Mark Plate



    A198523E01

  1. Using SST, fix the camshaft timing sprocket, and install the camshaft timing sprocket with the 3 bolts.

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

    Torque:
    20 N*m{ 204 kgf*cm , 15 ft.*lbf }



3. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    A198524

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

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }



4. INSTALL CHAIN TENSIONER SLIPPER


    A198525

  1. Install the chain tensioner slipper onto the cylinder block.



5. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    A200013E01

  1. Push in the plunger until the groove is aligned with the tensioner hole, and then insert a 1.1 mm (0.043 in.) diameter bar.



    A198527

  1. Install the chain tensioner with the 2 bolts.

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }

  1. Remove the 1.1 mm (0.043 in.) diameter bar from the chain tensioner.



    A198522E02

  1. Check that the mark plate and timing mark are in the positions shown in the illustration.
    Text in Illustration 
    *1
    		Timing Mark
    *2
    		Orange Mark Plate
    *3
    		Yellow Mark Plate



6. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    A198405

  1. Install the No. 2 timing chain cover with the clip.



7. CONNECT WATER INLET HOSE LH


A202793

  1. Connect the water inlet hose LH.

    HINT:
    The clip at the water inlet housing can be installed in any orientation, as long it does not contact any of the surrounding parts.



8. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY

  1. Align the key with the key groove of the crankshaft damper, and slide the crankshaft damper to the crankshaft.



    A204631E01

  1. Using SST, secure the crankshaft damper.

    SST
    09213-58014  
    09330-00021  

  1. Tighten the bolt to the specified torque.

    Torque:
    210 N*m{ 2141 kgf*cm , 155 ft.*lbf }



9. INSTALL NO. 2 TIMING CHAIN COVER


    A198405

  1. Install the No. 2 timing chain cover with the clip.



10. INSTALL ENGINE MOUNTING BRACKET RH

  1. Temporarily tighten the engine mounting bracket with the 4 bolts.



    A198404E01

  1. Fully tighten the 4 bolts, as shown in the illustration.

    Torque:
    55 N*m{ 561 kgf*cm , 41 ft.*lbf }



11. CHECK VALVE CLEARANCE


    A198346E01

  1. Set the No. 1 cylinder to TDC/Compression.
    Text in Illustration 
    *1
    		Timing Mark
    *2
    		TDC Mark

    1. Turn the crankshaft pulley until the grooves of the crankshaft damper and oil pump are aligned.

    2. Check that the timing mark of the camshaft timing sprocket is in the position shown in the illustration.

      HINT:
      If not, turn the crankshaft damper 1 revolution (360°) to align the timing mark and sprocket as above.



    A125843E03

  1. Check the valve clearance of the No. 1 cylinder exhaust valve and the No. 2 cylinder intake valve.
    Text in Illustration 
    *1
    		No. 1 Exhaust
    *2
    		No. 2 Intake
    *3
    		Camshaft
    *4
    		Feeler Gauge

    1. Using a feeler gauge, measure the clearance between the camshaft and No. 1 valve rocker arm.

      Valve clearance (cold):
      0.11 to 0.17 mm (0.004 to 0.007 in.) for intake
      0.14 to 0.20 mm (0.006 to 0.008 in.) for exhaust

      NOTICE:
      1. Insert the feeler gauge into the center of the roller surface, parallel to the No. 1 valve rocker arm.
      1. Do not apply excessive force to the valve adjusting screw when using adjusting tools such as SST and a screwdriver.

      HINT:
      If the clearance is not as specified, record the out-of-specification measurement, and then adjust the valve clearance.



    A125846E02

  1. Check the valve clearance of the No. 1 cylinder intake valve and the No. 3 cylinder exhaust valve.
    Text in Illustration 
    *1
    		No. 1 Intake
    *2
    		No. 3 Exhaust
    *3
    		Camshaft
    *4
    		Feeler Gauge

    1. Turn the crankshaft by a further 180° clockwise.

    2. Using a feeler gauge, measure the clearance between the camshaft and No. 1 valve rocker arm as shown in the illustration.

      Valve clearance (cold):
      0.11 to 0.17 mm (0.004 to 0.007 in.) for intake
      0.14 to 0.20 mm (0.006 to 0.008 in.) for exhaust

      NOTICE:
      1. Insert the feeler gauge into the center of the roller surface, parallel to the No. 1 valve rocker arm.
      2. Do not apply excessive force to the valve adjusting screw with adjusting tools when measuring or adjusting.

      HINT:
      If the clearance is not as specified, record the out-of-specification measurement, and then adjust the valve clearance.



    A125845E02

  1. Check the valve clearances of the No. 3 cylinder intake valve and No. 4 cylinder exhaust valve.
    Text in Illustration 
    *1
    		No. 3 Intake
    *2
    		No. 4 Exhaust
    *3
    		Camshaft
    *4
    		Feeler Gauge

    1. Turn the crankshaft clockwise by a further 180°.

    2. Using a feeler gauge, measure the clearance between the camshaft and No. 1 valve rocker arm as shown in the illustration.

      Valve clearance (cold):
      0.11 to 0.17 mm (0.004 to 0.007 in.) for intake
      0.14 to 0.20 mm (0.006 to 0.008 in.) for exhaust

      NOTICE:
      1. Insert the feeler gauge into the center of the roller surface, parallel to the No. 1 valve rocker arm.
      2. Do not apply excessive force to the valve adjusting screw with adjusting tools when measuring or adjusting.

      HINT:
      If the clearance is not as specified, record the out-of-specification measurement, and then adjust the valve clearance.



    A125850E02

  1. Check the valve clearances of the No. 2 cylinder intake valve and No. 4 cylinder intake valve.
    Text in Illustration 
    *1
    		No. 2 Exhaust
    *2
    		No. 4 Intake
    *3
    		Camshaft
    *4
    		Feeler Gauge

    1. Turn the crankshaft clockwise by a further 180°.

    2. Using a feeler gauge, measure the clearance between the camshaft and No. 1 valve rocker arm.

      Valve clearance (cold):
      0.11 to 0.17 mm (0.004 to 0.007 in.) for intake
      0.14 to 0.20 mm (0.006 to 0.008 in.) for exhaust

      NOTICE:
      1. Insert the feeler gauge into the center of the roller surface, parallel to the No. 1 valve rocker arm.
      2. Do not apply excessive force to the valve adjusting screw with adjusting tools when measuring or adjusting.

      HINT:
      If the clearance is not as specified, record the out-of-specification measurement, and then adjust the valve clearance.



12. ADJUST VALVE CLEARANCE


    A200014E02

  1. Using SST and a screwdriver, loosen the valve adjusting nut while keeping the valve adjusting screw in position.
    Text in Illustration 
    *1
    		Adjusting Screw
    *2
    		Lock Nut

    SST
    09248-56010  



    A200015E02

  1. Adjust valve clearance (intake side).
    Text in Illustration 
    *1
    		Adjusting Screw
    *2
    		Lock Nut
    *3
    		Feeler Gauge

    1. Insert a feeler gauge (0.14 mm (0.006 in.)) between the camshaft and No. 1 valve rocker arm, and turn the valve adjusting screw to adjust it.

      Valve clearance (cold):
      0.14 mm (0.006 in.)



      2. A200016E02

    2. Using SST and a screwdriver, tighten the valve adjusting nut while keeping the valve adjusting screw in position.
      Text in Illustration 
      *1
      		Adjusting Screw
      *2
      		Lock Nut

      Torque:
      With SST:
      13 N*m{ 133 kgf*cm , 10 ft.*lbf }
      Without SST:
      20 N*m{ 204 kgf*cm , 15 ft.*lbf }

      HINT:
      1. This torque wrench value can be obtained by using a torque wrench with a fulcrum length of 300 mm (11.81 in.) and SST with a fulcrum length of 150 mm (5.91 in.) (Click here).
      2. This torque value is effective when SST is parallel to a torque wrench.

  1. Adjust the valve clearance (exhaust side).

    Valve clearance (cold):
    0.17 mm (0.007 in.)

    HINT:
    Perform the same procedure as for the intake valve clearance adjustment.



13. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

  1. Install the cylinder head gasket onto the cylinder head cover.



    A198334E01

  1. Apply seal packing to the 4 locations shown in the illustration, and then install the cylinder head cover.

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

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Install the cylinder head cover within 3 minutes, and tighten the bolts within 15 minutes of applying the seal packing.



    A198344E01

  1. Temporarily tighten the cylinder head cover with the 12 bolts.

  1. Fully tighten the 12 bolts, as shown in the illustration.

    Torque:
    11 N*m{ 112 kgf*cm , 8 ft.*lbf }



14. INSTALL HARNESS BRACKET (w/o Air Conditioning System)


A202764

  1. Install the harness bracket with the bolt.

    Torque:
    13 N*m{ 130 kgf*cm , 9 ft.*lbf }



15. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


A204606

  1. Install the V-ribbed belt tensioner with the 2 bolts.

    Torque:
    24 N*m{ 245 kgf*cm , 18 ft.*lbf }



16. INSTALL IDLER PULLEY SUB-ASSEMBLY


A198403

  1. Install the idler pulley with the bolt.

    Torque:
    40 N*m{ 408 kgf*cm , 30 ft.*lbf }



17. INSTALL VACUUM PUMP ASSEMBLY

  1. Install 2 new O-rings to the vacuum pump.



    A204610

  1. Install the vacuum pump with the 2 bolts.

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }



18. INSTALL CAMSHAFT POSITION SENSOR


A208059

  1. Install the camshaft position sensor with the bolt.

    Torque:
    7.0 N*m{ 71 kgf*cm , 62 in.*lbf }

  1. Install the harness bracket with the bolt.

    Torque:
    11 N*m{ 112 kgf*cm , 8 ft.*lbf }



19. INSTALL NO. 2 CYLINDER HEAD COVER


A204126

  1. Install the No. 2 cylinder head cover.



    A204121

  1. Install the 2 harness brackets with the 2 bolts.

    Torque:
    11 N*m{ 112 kgf*cm , 8 ft.*lbf }



20. INSTALL OIL LEVEL DIPSTICK GUIDE

  1. Install a new O-ring to the oil level dipstick guide.



    A198410

  1. Install the oil level dipstick guide with the 2 bolts.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }



21. INSTALL ENGINE OIL LEVEL DIPSTICK


22. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY

  1. Install a new O-ring to the water by-pass pipe.



    A205776E01

  1. Install the water by-pass pipe with the 2 bolts, as shown in the illustration.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }



    A205778E01

  1. Connect the water by-pass hose.



    A194563E01

  1. Connect the oil cooler hose.



23. INSTALL NO. 4 WATER BY-PASS HOSE


A202772E01

  1. Install the No. 4 water by-pass hose.



24. INSTALL NO. 2 OIL COOLER HOSE


A202766E02
Text in Illustration 
*1
Paint Mark

  1. Install the No. 2 oil cooler hose.

    NOTICE:
    Align the oil cooler hose paint mark with the clamp center.



    A204117E02

  1. Install the hose clamp.
    Text in Illustration 
    *1
    		Paint Mark

    NOTICE:
    Align the oil cooler hose paint mark with the clamp center.



25. INSTALL SUPPLY PUMP DRIVE COUPLING


    A203011E01

  1. Install the supply pump drive coupling into the camshaft.
    Text in Illustration 
    *1
    		Camshaft
    *2
    		Supply Pump Drive Coupling

    NOTICE:
    Install the supply pump drive coupling in the correct direction.



26. TEMPORARILY TIGHTEN SUPPLY PUMP ASSEMBLY

NOTICE:
When installing, clean the seal surfaces of the fuel inlet pipe, supply pump and common rail.



    A202920

  1. Apply a light coat of engine oil to a new O-ring.

  1. Install the O-ring onto the supply pump.



    A196505

  1. Temporarily tighten the supply pump with the 3 bolts.



27. INSTALL FUEL INLET PIPE SUB-ASSEMBLY


A125732E01

NOTICE:
  1. When replacing the supply pump. the fuel inlet pipe must also be replaced.
  2. Replace the fuel inlet pipe with a new one when the fuel inlet pipe has been removed and reinstalled more than 5 times.



    A192977

  1. Temporarily tighten the fuel inlet pipe onto the supply pump and common rail.

    NOTICE:
    Install the pipe and union nut vertically. not at a tilt.

  1. Fully tighten the supply pump with the 3 bolts.

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }

  1. Using a union nut wrench (17 mm), tighten the fuel inlet pipe union nut on the common rail side.

    Torque:
    28 N*m{ 286 kgf*cm , 20 ft.*lbf }

    NOTICE:
    Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Click here).

  1. Using a wrench (17 mm), hold the supply pump nut, and using a union nut wrench (17 mm), tighten the fuel inlet pipe union nut on the supply pump side.

    Torque:
    28 N*m{ 286 kgf*cm , 20 ft.*lbf }

    NOTICE:
    Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Click here).



28. CONNECT NO. 2 FUEL HOSE


A194600

  1. Connect the No. 2 fuel hose.



29. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY


A199744


  1. Install the nozzle leakage pipe into each injector.



    1. Make sure the lock bush is at top position.


      A199765E01

      Text in Illustration 
      *1
      		Lock Bush
      *2
      		Return Plug
      *3
      		Rest Arm
      *4
      		Injector

    2. Insert the rest arm into the injector and push both sides of the return plug until the rest arm engages with the injector, as shown in the illustration.

      HINT:
      Push the nozzle leakage pipe until it makes a click sound.

    3. Push the lock bush until the it fits with the return plug, as shown in the illustration.



    A194598

  1. Connect the nozzle leakage pipe and install new retainer spring onto the supply pump.



30. INSTALL NOZZLE LEAKAGE PIPE SET CLAMP


A198350

  1. Install the 3 nozzle leakage pipe set clamps.



31. INSTALL NO. 2 INJECTION PIPE CLAMP


    A202912

  1. Install both sides of the No. 2 injection pipe clamp with the nut as shown in the illustration.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }



32. INSTALL INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY

  1. Install the new gasket to the cylinder head.



    A202770

  1. Install the intake air connector with the diesel throttle body with the 2 bolts and 2 nuts.

    Torque:
    23 N*m{ 235 kgf*cm , 17 ft.*lbf }



33. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY

  1. Install a new gasket.



    A057108E10

  1. Apply adhesive to the 2 bolts.
    Text in Illustration 
    *1
    		Adhesive

    Adhesive:
    Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.



    A202807E02

  1. Install the electric EGR control valve with the 2 bolts.
    Text in Illustration 
    *1
    		EGR Control Valve

    Torque:
    23 N*m{ 235 kgf*cm , 17 ft.*lbf }

  1. Connect the No. 3 water by-pass hose.

  1. Connect the No. 4 water by-pass hose.



34. INSTALL HARNESS BRACKET


A198412

  1. Install the harness bracket with the bolt.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }

  1. Connect the vacuum hose to the vacuum pump.



35. INSTALL NO. 1 EGR COOLER BRACKET


A202806

  1. Install the No. 1 EGR cooler bracket with the 2 bolts.

    Torque:
    23 N*m{ 235 kgf*cm , 17 ft.*lbf }

  1. Connect the vacuum hose.



36. INSTALL EGR WITH COOLER PIPE ASSEMBLY

  1. Install 2 new gaskets.



    A202805

  1. Install the EGR with cooler pipe assembly with the 4 bolts and 2 nuts.

    Torque:
    23 N*m{ 235 kgf*cm , 17 ft.*lbf }



    A202803E01

  1. Connect the No. 2 water by-pass hose.

  1. Connect the No. 2 oil cooler hose.

  1. Connect the 2 vacuum hoses and No. 1 oil hose.



    A202802E01

  1. Connect the No. 1 vacuum transmitting hose.

  1. Connect the vacuum transmitting hose.



37. INSTALL GENERATOR BRACKET


A198402

  1. Install the No. 1 generator bracket with the bolt.

    Torque:
    40 N*m{ 407 kgf*cm , 30 ft.*lbf }



38. INSTALL GENERATOR ASSEMBLY


A198401E01

  1. Install the generator with the 2 bolts and nut.

    Torque:
    Bolt A:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }
    Bolt B, Nut:
    54 N*m{ 551 kgf*cm , 40 ft.*lbf }



39. INSTALL ENGINE ASSEMBLY

  1. Install the engine assembly (Click here).