Installation

3UZ-FE ENGINE MECHANICAL: CAMSHAFT (for Bank 2): INSTALLATION

INSTALLATION

1. INSTALL CAMSHAFT SUB GEAR

(a) Install the bolt washer, sub gear and wave washer.
HINT: Attach the pins on the gears to the gear bolt washer ends.

(b) Using snap ring pliers, install the snap ring.

(d) Using SST, align the holes of the driven main gear and sub gear by turning the sub gear clockwise, and temporarily install a service bolt.
SST: 09960-10010
09962-01000
09963-00500
(e) Align the gear teeth of the driven main gear and sub gear, and tighten the service bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
2. INSTALL CAMSHAFT TIMING TUBE ASSEMBLY

(a) Insert a new oil seal into the camshaft timing tube until it reaches the stopper.
- Be careful of the installation direction.
- Do not turn over the lip of the oil seal.

(b) Align the timing tube knock pin with the knock pin groove of the drive gear, and temporarily install the drive gear with the 4 bolts.

(c) Using SST and a 5 mm hexagon wrench, uniformly tighten the 4 bolts in several passes in the sequence shown in the illustration.
SST: 09960-10010
09962-01000
09963-00500
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
NOTE:
Be careful not to damage the timing tube.

(d) Mount the hexagon head portion of the camshaft in a vise between aluminum plates.
NOTE:
Be careful not to damage the camshaft.

(e) Align the camshaft knock pin with the knock pin groove of the timing tube, and push the timing tube by hand until it touches the bottom.
(f) Using a 10 mm hexagon wrench, install the bolt.
Torque: 78 Nm (795 kgf-cm, 58 ft-lbf)
(g) Install the seal washer and screw plug.
Torque: 15 Nm (152 kgf-cm, 11 ft-lbf)
3. INSTALL CAMSHAFT AND NO. 2 CAMSHAFT
NOTE:
Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

(a) Set the crankshaft position.
(1) Check that the set key of the crankshaft is at a position 45° counterclockwise from the timing mark (1 dot mark) of the oil pump body.
NOTE:
The crankshaft must be at the correct angle to avoid damage in later steps. If the crankshaft is at the wrong angle and then the camshaft is installed, the piston head and valve head may come in contact and be damaged.

(b) Apply MP grease to the thrust portion of the camshafts.

(c) Align the timing marks (1 dot mark each) of the camshaft drive and driven main gears, and place the 2 camshafts.
(d) Set the timing marks (1 dot mark each) of the camshaft drive and driven main gears at an approximately 10° angle.

(e) Apply seal packing to the camshaft housing plug.
(1) Remove the old packing (FIPG) material.
(2) Apply seal packing to the housing plug as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

(f) Install the camshaft housing plug to the cylinder head as shown in the illustration.
(g) Install the oil control valve filter to the cylinder head.
NOTE:
Be careful of the installation direction.

(h) Apply seal packing to the front bearing cap.
(1) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the bearing cap and cylinder head.
(2) Apply seal packing to the bearing cap as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal diameter:
1.5 to 2.0 mm (0.059 to 0.079 in.)
NOTE:
Do not apply seal packing to the front bearing cap grooves.

(i) Install the front bearing cap.
HINT: Installing the front bearing cap will determine the thrust portion of the camshaft.

(j) Push in the camshaft setting oil seal.

(k) Install the other bearing caps in the sequence shown, with the arrow marks facing forward.

(l) Install new seal washers to the bearing cap bolts A and B.
Bolt length:
94 mm (3.70 in.) for A with seal washer
72 mm (2.83 in.) for B with seal washer
(m) Apply a light coat of engine oil on the threads f the bearing cap bolt A and B.
NOTE:
Do not apply engine oil under the heads of the bearing cap bolts A and B.

(n) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts C, D and E.
Bolt length:
25 mm (0.98 in.) for C
52 mm (2.05 in.) for D
38 mm (1.50 in.) for E
(o) Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration below.
NOTE:
Install the pipe with the "E[down]" mark facing towards the exhaust side.

(p) Uniformly tighten the 22 bearing cap bolts in several passes in the sequence shown in the illustration.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)

(q) Remove the service bolt.
4. INSTALL CAMSHAFT TIMING PULLEY SUB-ASSEMBLY RH

(a) Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
(b) Attach the timing pulley to the camshaft timing tube. Face the timing pulley's "R" mark forward.
(c) Hold the camshaft with a wrench and install the 4 pulley bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
5. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH

(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder heads as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE:
- Remove any oil from the contact surface.
- Install the oil pan within 5 minutes after applying seal packing.
- Do not start the engine within 2 hours after applying seal packing.

(c) Install the gasket to the cylinder head cover.
(d) Install the seal washer to the bolt.

(e) Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several passes.
Torque: 6.0 Nm (61 kgf-cm, 53 in-lbf)

(f) Connect the engine wire protector to the cylinder head cover.
(g) Connect the wire harness clamp to the camshaft bearing cap.
6. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY RH Installation
7. INSTALL NO. 2 TIMING BELT IDLER SUB-ASSEMBLY Reassembly
8. INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY Reassembly
9. INSTALL TIMING BELT Installation
10. INSTALL CRANKSHAFT POSITION SENSOR PLATE Installation
11. INSTALL TIMING GEAR COVER SPACER Installation
12. INSTALL NO. 1 TIMING BELT COVER Installation
13. INSTALL CRANKSHAFT PULLEY Installation
14. INSTALL IDLER PULLEY ASSEMBLY Installation
15. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Installation
16. INSTALL NO. 2 TIMING BELT COVER SUB-ASSEMBLY Installation
17. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY Installation
18. INSTALL NO. 3 TIMING BELT COVER SUB-ASSEMBLY LH Installation
19. INSTALL NO. 3 TIMING BELT COVER SUB-ASSEMBLY RH Installation
20. INSTALL SPARK PLUG Installation
21. INSTALL IGNITION COIL ASSEMBLY Installation
22. CONNECT COOLER COMPRESSOR ASSEMBLY Installation
23. INSTALL GENERATOR ASSEMBLY Installation
24. INSTALL VANE PUMP ASSEMBLY Installation
25. INSTALL FAN AND GENERATOR V BELT Installation
26. INSTALL RADIATOR ASSEMBLY Installation
27. CONNECT NO. 1 OIL COOLER OUTLET TUBE Installation
28. CONNECT NO. 1 OIL COOLER INLET TUBE Installation
29. CONNECT NO. 2 RADIATOR HOSE Installation
30. CONNECT NO. 1 RADIATOR HOSE Installation
31. INSTALL AIR CLEANER ASSEMBLY Installation
32. INSTALL INTAKE AIR CONNECTOR PIPE Installation
33. INSTALL NO. 1 AIR CLEANER INLET Installation
34. INSTALL V-BANK COVER Installation
35. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
36. ADD ENGINE COOLANT Service and Repair
37. CHECK FOR COOLANT LEAK Testing and Inspection
38. INSTALL ENGINE UNDER COVER
39. CHECK IGNITION TIMING Engine
40. PERFORM INITIALIZATION
(a) Perform initialization Repair Instruction - Initialization.
NOTE:
Certain systems need to be initialized after disconnecting the cable from the negative (-) battery terminal.