Diesel Data: Automotive Repair
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Installation








2GR-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION

INSTALLATION

1. INSTALL NO. 3 CAMSHAFT
(a) Apply a light coat of engine oil to the No. 3 camshaft journals and camshaft housing sub-assembly LH.
(b) Install the No. 3 camshaft to the camshaft housing sub-assembly LH.
2. INSTALL NO. 4 CAMSHAFT
(a) Apply a light coat of engine oil to the No. 4 camshaft journals and camshaft housing sub-assembly LH.
(b) Install the No. 4 camshaft to the camshaft housing sub-assembly LH.
3. INSTALL CAMSHAFT BEARING CAP (for Bank 2)
(a) Apply engine oil to the camshaft bearing caps.





(b) Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.





(c) Temporarily tighten the 8 bolts in the order shown in the illustration.
Torque: 10 Nm (102 kgf-cm, 7ft-lbf)
4. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH





(a) Make sure that the valve rocker arm is installed as shown in the illustration.

Text in Illustration









(b) Apply seal packing in a continuous line as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal diameter:
3.5 to 4.5 mm (0.138 to 0.177 in.)

NOTICE:
- Remove any oil from the contact surface.
- Install the camshaft housing sub-assembly LH within 3 minutes.
- Do not start the engine for at least 2 hours after installing.





(c) Install the camshaft housing sub-assembly LH and tighten the 13 bolts in the order shown in the illustration.
Torque: 28 Nm (286 kgf-cm, 21ft-lbf)

NOTICE:
- When installing the camshaft housing sub-assembly LH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.
- If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly LH, clean the installation surfaces, and reapply seal packing.
- If the camshaft housing sub-assembly LH 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.





(d) Tighten the 8 bolts in the order shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12ft-lbf)
5. INSTALL CAMSHAFT
(a) Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly RH.
(b) Install the camshaft to the camshaft housing sub-assembly RH.
6. INSTALL NO. 2 CAMSHAFT
(a) Apply a light coat of engine oil to the No. 2 camshaft journals and camshaft housing sub-assembly RH.
(b) Install the No. 2 camshaft to the camshaft housing sub-assembly RH.
7. INSTALL CAMSHAFT BEARING CAP (for Bank 1)
(a) Apply engine oil to the camshaft bearing caps.





(b) Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.





(c) Temporarily tighten the 8 bearing cap bolts in the order shown in the illustration.
Torque: 10 Nm (102 kgf-cm, 7ft-lbf)
8. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH





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

Text in Illustration









(b) Apply seal packing in a continuous line as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal diameter:
3.5 to 4.5 mm (0.138 to 0.177 in.)

NOTICE:
- Remove any oil from the contact surface.
- Install the camshaft housing sub-assembly RH within 3 minutes.
- Do not start the engine for at least 2 hours after installing.





(c) Install the camshaft housing sub-assembly RH and tighten the 12 bolts in the order shown in the illustration.
Torque: 28 Nm (286 kgf-cm, 21ft-lbf)

NOTICE:
- When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown in the illustration.
Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.
- If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly RH, clean the installation surfaces, and reapply seal packing.
- If the camshaft housing sub-assembly RH 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.





(d) Tighten the 8 bolts in the order shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12ft-lbf)
9. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY





(a) Install the No. 3 chain tensioner assembly with the bolt.
Torque: 21 Nm (214 kgf-cm, 15ft-lbf)
(b) While pushing in the tensioner, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold it.
10. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)





(a) Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.

Text in Illustration





(b) Apply a light coat of engine oil to the bolt threads and bolt-seating surface.
(c) Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear LH with the No. 2 chain sub-assembly installed.





(d) Using SST to hold the hexagonal portion of each camshaft, tighten the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly LH.
SST: 09922-10010
Torque: 100 Nm (1020 kgf-cm, 74ft-lbf)
(e) Remove the pin from the No. 3 chain tensioner assembly.
11. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY





(a) Install the No. 2 chain tensioner assembly with the bolt.
Torque: 21 Nm (214 kgf-cm, 15ft-lbf)
(b) While pushing in the No. 2 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold it.
12. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)





(a) Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.

Text in Illustration





(b) Apply a light coat of engine oil to the bolt threads and bolt-seating surface.
(c) Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the No. 2 chain sub-assembly installed.





(d) Using SST to hold the hexagonal portion of each camshaft, tighten the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly RH.
SST: 09922-10010
Torque: 100 Nm (1020 kgf-cm, 74ft-lbf)
(e) Remove the pin from the No. 2 chain tensioner assembly.
13. INSTALL IDLE SPROCKET ASSEMBLY Reassembly
14. INSTALL CHAIN SUB-ASSEMBLY Reassembly
15. INSTALL CHAIN TENSIONER SLIPPER Reassembly
16. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Reassembly
17. INSPECT VALVE TIMING Reassembly
18. INSTALL TIMING CHAIN CASE OIL SEAL Installation
19. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Installation
20. INSTALL WATER INLET HOUSING Reassembly
21. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH Reassembly
22. INSTALL OIL PAN SUB-ASSEMBLY Reassembly
23. INSTALL OIL STRAINER SUB-ASSEMBLY Reassembly
24. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY Reassembly
25. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1) Reassembly
26. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH (for Bank 2) Reassembly
27. INSTALL CRANKSHAFT PULLEY Installation
28. INSTALL NO. 1 OIL PIPE Reassembly
29. INSTALL OIL PIPE Reassembly
30. INSTALL CRANKSHAFT POSITION SENSOR Installation
31. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY Installation
32. INSTALL RADIO SETTING CONDENSER Installation
33. INSTALL WATER PUMP PULLEY Installation
34. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY Installation
35. INSTALL NO. 2 TIMING GEAR COVER Installation
36. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Installation
37. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH Installation
38. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Installation
39. INSTALL NO. 2 MANIFOLD STAY Installation
40. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE Reassembly
41. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE Installation
42. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH Installation
43. INSTALL INTAKE MANIFOLD Installation
44. INSTALL NO. 2 ENGINE MOUNTING STAY RH Installation
45. INSTALL IGNITION COIL ASSEMBLY Installation
46. INSTALL THROTTLE BODY BRACKET Installation
47. INSTALL NO. 1 SURGE TANK STAY Installation
48. INSTALL INTAKE AIR SURGE TANK ASSEMBLY Installation
49. INSTALL ENGINE HANGER Installation
50. REMOVE ENGINE FROM ENGINE STAND
51. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Installation
52. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD)
HINT: See the steps from "Install Automatic Transaxle Assembly" through "Install Engine Assembly with Transaxle" .

53. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for AWD)
HINT: See the steps from "Install Automatic Transaxle Assembly" through "Install Engine Assembly with Transaxle" Installation.
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