NR Series ENGINE MECHANICAL  CAMSHAFT  INSTALLATION  

13801 1.SET NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

a.

1.156,0.677 1.438,0.677 false 0.365,0.635 0.646,0.635 false 0.323,1.448 0.604,1.448 false 0.198,0.563 0.51,0.719 0.313,0.156 10 false *1 0.146,1.365 0.458,1.521 0.313,0.156 10 false *2 1.5,0.604 1.813,0.76 0.313,0.156 10 false *3 0.802,0.188 1.115,0.344 0.313,0.156 10 false *a 2.281,0.198 2.594,0.354 0.313,0.156 10 false *b

*1	No. 1 Valve Rocker Arm Sub-assembly
*2	Valve Lash Adjuster Assembly
*3	Valve Stem Cap
*a	Correct
*b	Incorrect

Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.

11103 2.INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

a.

1.781,2.792 1.781,2.188 true 1.708,2.854 2.021,3.052 0.313,0.198 10 false *a

*a	Seal Packing

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 Packing Diameter:

3.5 to 4.0 mm (0.138 to 0.157 in.)

NOTICE:

·

Remove any oil from the contact surface.

·

Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

·

Do not start the engine for at least 2 hours after installation.

b.

Set the camshaft housing sub-assembly to the cylinder head sub-assembly.

c.

2.917,1.406 3.073,1.604 0.156,0.198 10 true 1 2.042,0.292 2.198,0.49 0.156,0.198 10 false 2 0.344,1.073 0.5,1.271 0.156,0.198 10 false 3 2.969,0.51 3.125,0.708 0.156,0.198 10 false 4

Tighten the 4 bolts in the order shown in the illustration.

Torque:

28 N*m (286 kgf*cm, 21 ft.*lbf)

15678A 3.INSTALL OIL CONTROL VALVE FILTER

13512 4.INSTALL NO. 2 CAMSHAFT

13511 5.INSTALL CAMSHAFT

6.INSTALL CAMSHAFT BEARING CAP

16671 7.INSTALL WATER VALVE

13070A 8.INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

13050 9.INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

10.SET NO. 1 CYLINDER TO TDC/COMPRESSION

13506 11.INSTALL CHAIN SUB-ASSEMBLY

HINT:

·

Be sure to install the chain sub-assembly with the mark plates facing away from the engine assembly.

·

Pass the chain sub-assembly through the timing chain guide.

a.

Temporarily install the crankshaft pulley set bolt.

b.

Install the timing chain guide with the 2 bolts to the cylinder head sub-assembly and cylinder block sub-assembly.

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf)

c.

Align the mark plates (gold) with the timing marks as shown in the illustration and install the chain sub-assembly.

1.667,0.854 2.833,0.854 true 2.906,0.76 4.24,0.76 true 0.708,3.115 1.781,1.865 1.781,1.865 2.802,3.042 true 0.708,3.25 2.396,4.469 2.396,4.469 2.844,3.208 true 1.479,0.781 1.792,0.938 0.313,0.156 10 false *b 1.719,1.688 2.031,1.844 0.313,0.156 10 false *a 2.323,4.521 2.635,4.677 0.313,0.156 10 false *b 4.281,0.698 4.594,0.854 0.313,0.156 10 false *a

*a

Mark Plate (Gold)

*b

Timing Mark

HINT:

Do not pass the chain sub-assembly around the sprocket of the camshaft timing gear assembly. Only place it on the sprocket.

d.

Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly clockwise.

HINT:

To tension the chain sub-assembly, slowly turn the camshaft timing gear assembly clockwise to prevent the chain sub-assembly from being misaligned.

e.

1.552,1.563 2.031,0.271 2.031,0.271 1.521,1.49 true 0.604,1.906 1.375,1.615 true 1.469,1.844 0.615,1.906 0.615,1.906 1.302,1.385 true 1.979,0.115 2.292,0.271 0.313,0.156 10 false *a 0.323,1.854 0.552,2.01 0.229,0.156 10 true *b

*a	Timing Mark
*b	Mark Plate (Gold)

Align the mark plate (gold) and timing mark and install the chain sub-assembly to the crankshaft timing sprocket.

NOTICE:

The mark for the crankshaft spans 3 outer links. Use the center mark plate for the alignment.

f.

Remove the crankshaft pulley set bolt from the crankshaft.

13559 12.INSTALL CHAIN TENSIONER SLIPPER

13540 13.INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

14.CHECK NO. 1 CYLINDER TDC/COMPRESSION

16322 15.INSTALL WATER INLET PIPE

11302A 16.INSTALL TIMING CHAIN COVER OIL SEAL

11310 17.INSTALL TIMING CHAIN COVER ASSEMBLY

13470 18.INSTALL CRANKSHAFT PULLEY ASSEMBLY

11191A 19.INSTALL SPARK PLUG TUBE GASKET

11213 20.INSTALL CYLINDER HEAD COVER GASKET

21.ADD ENGINE OIL

11201 22.INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

15370 23.INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side)

15370 24.INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side)

29300 25.INSTALL VACUUM PUMP ASSEMBLY

11452 26.INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

16206 27.INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY

23818 28.INSTALL FUEL VAPOR FEED PIPE

19500D 29.INSTALL NO. 1 IGNITION COIL

23100X 30.INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY

23250 31.INSTALL FUEL INJECTOR ASSEMBLY

17201 32.INSTALL TURBOCHARGER SUB-ASSEMBLY

33.INSTALL ENGINE HANGERS

34.REMOVE ENGINE ASSEMBLY FROM ENGINE STAND