Installation

2GR-FSE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION

1. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

(a) Clamp the camshaft in a vise.

NOTICE:
Be careful not to damage the camshaft in the vise.

(b) Put the camshaft timing gear assembly and camshaft together by aligning the pin hole and straight pin.

Text in Illustration

(c) Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the hole.

NOTICE:
Be sure not to turn the camshaft timing gear assembly in the retard direction.

(d) Check that there is no clearance between the camshaft timing gear assembly flange and camshaft.

(e) Install the flange bolt while holding the camshaft.

Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf)

(f) Check the lock of the camshaft timing gear assembly.

(1) Secure the camshaft in place and confirm that the camshaft timing gear assembly is locked.

NOTICE:
Be careful not to damage the camshaft.

2. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

(a) Clamp the camshaft in a vise.

NOTICE:
Be careful not to damage the camshaft in the vise.

(b) Put the camshaft timing exhaust gear assembly and camshaft together by aligning the pin hole and straight pin.

Text in Illustration

(c) Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the hole.

NOTICE:
Be sure not to turn the camshaft timing exhaust gear in the advanced direction.

(d) Check that there is no clearance between the gear flange and camshaft.

(e) Install the flange bolt while holding the camshaft.

Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf)

(f) Check the camshaft timing exhaust gear lock.

(1) Make sure that the camshaft timing exhaust gear assembly locks.

3. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY

(a) Check that the notch is aligned with the "0" timing mark of the timing chain cover.

(b) Align the mark plate (yellow) with the timing mark of the camshaft timing gear as shown in the illustration and install the No. 2 chain to the camshaft timing gear.

Text in Illustration

(c) Clean the camshaft housing LH and camshaft journals, and apply engine oil to them.

(d) Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.

Text in Illustration

(e) Install the chain to the No. 3 camshaft, and then install the camshaft to the camshaft housing LH.

Text in Illustration

HINT
* Place the chain on the camshaft timing gear but do not engage the teeth of the sprocket and the chain.
* Install the camshaft so that the timing mark is facing upward.

4. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY

(a) Clean the camshaft housing LH and camshaft journals, and apply engine oil to them.

(b) Pass the No. 4 camshaft through the No. 2 chain from the front of the vehicle, align the mark plate (yellow) with the timing mark and install the No. 2 chain to the camshaft timing exhaust gear.

Text in Illustration

(c) While lifting up the No. 4 camshaft, pass the No. 3 chain tensioner assembly through the No. 2 chain and set it in place.

(d) Install the No. 4 camshaft to the camshaft housing LH, and then install the No. 3 chain tensioner assembly with the bolt.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

5. INSTALL CAMSHAFT BEARING CAP (for Bank 2)

(a) Clean the camshaft bearing caps and apply engine oil to them.

(b) Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.

Text in Illustration

(c) Check the marks and numbers on the camshaft bearing caps, and then remove the service bolts and washers in the order shown in the illustration. Immediately after removing the service bolts and washers in the location for bearing caps, install the bearing caps with the bolts in the order shown in the illustration.

for Bolt A - Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)

for Bolt B - Torque : 16 Nm (163 kgf-cm, 12 ft-lbf)

Text in Illustration

NOTICE:
* Be sure to follow the numerical order when performing this procedure.
* Do not drop the service bolts and washers into the cylinder head.

(d) Check the torque of each bolt again.

6. INSTALL CHAIN SUB-ASSEMBLY

(a) Align the paint marks on the camshaft timing gear and No. 1 chain, and install the No. 1 chain to the camshaft timing gear.

Text in Illustration

HINT
If the paint marks are not aligned, align them by turning the camshaft slightly.

7. INSTALL CAMSHAFT

(a) Turn the crankshaft clockwise until it is in the position shown in the illustration so that the chain can be installed easily.

HINT
When turning the crankshaft, engine oil may spray out of the oil holes.

(b) Align the mark plate (yellow) with the timing mark of the camshaft timing gear as shown in the illustration and install the No. 2 chain to the camshaft timing gear.

Text in Illustration

(c) Clean the camshaft housing RH and camshaft journals and apply engine oil to them.

(d) Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.

Text in Illustration

(e) Install the chain to the camshaft, and then install the camshaft to the camshaft housing RH.

Text in Illustration

HINT
* Place the chain on the camshaft timing gear but do not engage the teeth of the sprocket and the chain.
* Install the camshaft so that the timing mark is facing upward.

8. INSTALL NO. 2 CAMSHAFT

(a) Clean the camshaft housing RH and camshaft journals, and apply engine oil to them.

(b) Pass the No. 2 camshaft through the No. 2 chain from the front of the vehicle, align the mark plate (yellow) with the timing mark and install the No. 2 chain to the camshaft timing exhaust gear.

Text in Illustration

(c) While lifting up the No. 2 camshaft, pass the No. 2 chain tensioner assembly through the No. 2 chain and set it in place.

(d) Install the No. 2 camshaft to the camshaft housing RH, and then install the No. 2 chain tensioner assembly with the bolt.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

9. INSTALL CAMSHAFT BEARING CAP (for Bank 1)

(a) Clean the camshaft bearing caps and apply engine oil to them.

(b) Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.

Text in Illustration

for Bolt A - Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)

for Bolt B - Torque : 16 Nm (163 kgf-cm, 12 ft-lbf)

Text in Illustration

NOTICE:
* Be sure to follow the numerical order when performing this procedure.
* Do not drop the service bolts and washers into the cylinder head.

(d) Check the torque of each bolt again.

10. INSTALL CHAIN SUB-ASSEMBLY

(a) Align the paint marks on the camshaft timing gear and chain, and install the chain to the camshaft timing gear.

Text in Illustration

HINT
If the paint marks are not aligned, align them by turning the camshaft slightly.

11. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Turn the crankshaft counterclockwise 30° past the "0" timing mark, and then turn it clockwise to align the notch with the "0" timing mark.

(b) Turn the crankshaft slightly to eliminate the slack in the chain.

HINT
Make sure there is some slack in the chain around the area where the chain tensioner is installed.

(c) While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration.

Text in Illustration

(d) While turning the stopper plate of the tensioner counterclockwise, insert a pin of 1.27 mm diameter (0.0500 in.) into the holes in the stopper plate and tensioner to secure the stopper plate in place.

(e) Install the chain tensioner with the 2 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(f) Remove the pin from the No. 1 chain tensioner.

12. INSPECT VALVE TIMING

(a) Check the camshaft timing marks.

NOTICE:
* Check each timing mark from a viewpoint directly in line with the center of the camshaft and the timing mark on each camshaft timing gear.
* If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.

(b) Check that each camshaft timing mark is positioned as shown in the illustration.

Text in Illustration

NOTICE:
For Intake Camshaft: Be sure to check mark A at the point when marks B, C and D are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.

(c) If the valve timing is misaligned, reinstall the timing chain.

(d) Turn the crankshaft 2 revolutions, set the No. 1 cylinder to TDC / compression and check the timing marks again.

13. INSTALL TIMING CHAIN COVER PLATE

(a) Install a new gasket and the timing chain cover plate with the 4 bolts.

Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

14. POUR ENGINE OIL

HINT
Before installing the cylinder head cover, pour engine oil into the locations shown in the illustration.

15. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Install 3 new gaskets as shown in the illustration.

(b) Install a new gasket to the head cover.

(c) Apply seal packing as shown in the illustration.

Text in Illustration

Seal packing:

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

NOTICE:
* Remove any oil from the contact surfaces.
* Install the head cover within 3 minutes of applying seal packing.
* Do not start the engine for at least 2 hours after installation.

(d) Install the cylinder head cover sub-assembly with the 14 bolts.

for bolt A - Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

for bolts except A - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(e) Install the bolt and ground wire.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

HINT
Make sure the removed parts are returned to the same places they were removed from.

16. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

(a) Install 3 new gaskets as shown in the illustration.

(b) Install a new gasket to the head cover.

(c) Apply seal packing as shown in the illustration.

Text in Illustration

for bolt A - Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

for bolts except A - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(e) Install the bolt and ground wire.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

HINT
Make sure the removed parts are returned to the same places they were removed from.

17. INSTALL NO. 2 OIL PIPE Reassembly

18. INSTALL NO. 1 OIL PIPE Reassembly

19. INSTALL SPARK PLUG Installation

20. INSTALL IGNITION COIL ASSEMBLY Installation

21. INSTALL INJECTOR DRIVER Installation

22. INSTALL NO. 1 ENGINE COVER Installation

23. INSTALL GENERATOR ASSEMBLY

Installation.

24. INSTALL FUEL PUMP ASSEMBLY

Installation.

25. INSTALL BATTERY

Installation.