Installation
1NR-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION
1. INSTALL VALVE LASH ADJUSTER ASSEMBLY Reassembly
2. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Reassembly
3. INSTALL CAMSHAFT
(a) Clean the camshaft journals.
(b) Apply a light coat of engine oil to the camshaft journals and camshaft housing.
(c) Install the camshaft to the camshaft housing.
4. INSTALL NO. 2 CAMSHAFT
(a) Clean the camshaft journals.
(b) Apply a light coat of engine oil to the camshaft journals and camshaft housing.
(c) Install the No. 2 camshaft to the camshaft housing.
5. INSTALL CAMSHAFT BEARING CAP
(a) Apply engine oil to the bearing caps.
(b) Install the 5 bearing caps to the camshaft housing.
(c) Tighten the 5 bolts in the order shown in the illustration.
Torque : 16 Nm (163 kgf-cm, 12 ft-lbf)
6. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY
(a) Apply seal packing in a continuous bead as shown in the illustration.
Text in Illustration
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Bead diameter:
3.5 to 4.0 mm (0.138 to 0.158 in.)
NOTICE:
* Remove any oil from the contact surfaces.
* Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing.
(b) Set the crankshaft in the position (40° BTDC) shown in the illustration.
Text in Illustration
NOTICE:
Turn the crankshaft clockwise when positioning the No. 1 cylinder after the camshaft housing sub-assembly is installed.
HINT
Make sure that the timing mark of the crankshaft is positioned as shown in the illustration.
(c) Set the camshaft and No. 2 camshaft as shown in the illustration.
Text in Illustration
HINT
Make sure that the straight pin of the camshaft is positioned as shown in the illustration.
(d) Install the camshaft housing and tighten the 18 bolts in the order shown in the illustration.
Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)
NOTICE:
* After installing the camshaft housing, make sure that the cam lobes are positioned as shown in the illustration.
* If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
* If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
* After installing the camshaft housing, wipe off any seal packing that seeped out from between the housing and the cylinder head.
7. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
(a) Check that the straight pin is installed on the camshaft.
Text in Illustration
(b) Put the camshaft timing gear and camshaft together by aligning the straight pin hole and straight pin.
NOTICE:
* Do not forcefully push in the camshaft timing gear assembly. This may cause the camshaft straight pin tip to damage the installation surface of the camshaft timing gear assembly.
* Do not turn the camshaft timing gear in the retard direction (clockwise).
(c) Tighten the flange bolt with the camshaft timing gear secured in place.
Text in Illustration
Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)
(d) Check that the camshaft timing gear can move in the retard direction (clockwise) and locks in the most retarded position.
Text in Illustration
8. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
(a) Check that the straight pin is installed on the No. 2 camshaft.
Text in Illustration
(b) Put the camshaft timing exhaust gear and No. 2 camshaft together by aligning the straight pin hole and straight pin.
NOTICE:
Do not forcefully push in the camshaft timing gear assembly. This may cause the camshaft straight pin tip to damage the installation surface of the camshaft timing gear assembly.
(c) Tighten the flange bolt with the camshaft timing exhaust gear secured in place.
Text in Illustration
Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)
(d) Make sure that the camshaft timing exhaust gear is locked.
9. INSTALL TIMING CHAIN GUIDE Reassembly
10. INSTALL CHAIN SUB-ASSEMBLY Reassembly
11. INSTALL TIMING CHAIN TENSION ARM Reassembly
12. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Reassembly
13. INSTALL TIMING CHAIN COVER OIL SEAL Installation
14. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Installation
15. INSTALL CRANKSHAFT PULLEY Reassembly
16. INSTALL WATER PUMP PULLEY Reassembly
17. INSTALL CRANKSHAFT POSITION SENSOR Reassembly
18. INSTALL CAMSHAFT BEARING CAP OIL HOLE GASKET Reassembly
19. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Reassembly
20. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Installation
21. INSTALL NO. 2 IDLE PULLEY ASSEMBLY WITH BRACKET Installation
22. INSTALL NO. 1 WATER BY-PASS PIPE Installation
23. INSTALL NO. 2 VENTILATION HOSE Installation
24. INSTALL VENTILATION HOSE Installation
25. INSTALL NO. 1 IGNITION COIL Installation
26. INSTALL INJECTOR VIBRATION INSULATOR Installation
27. INSTALL NO. 1 DELIVERY PIPE SPACER Installation
28. INSTALL FUEL INJECTOR ASSEMBLY Installation
29. INSTALL FUEL DELIVERY PIPE Installation
30. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE Installation
31. INSTALL ENGINE OIL LEVEL DIPSTICK
32. INSTALL NO. 4 ENGINE WIRE Installation
33. INSTALL INTAKE MANIFOLD ASSEMBLY Installation
34. INSTALL INTAKE MANIFOLD STAY Installation
35. CONNECT NO. 4 WATER BY-PASS HOSE Installation
36. CONNECT NO. 2 WATER BY-PASS HOSE Installation
37. CONNECT VENTILATION HOSE Installation
38. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY Installation
39. INSTALL MANIFOLD STAY Installation
40. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Installation
41. INSTALL GENERATOR ASSEMBLY Installation
42. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
Installation