Camshaft Installation

Fix the camshaft in place.

NOTICE:

Be careful not to damage the camshaft.

Lightly press and turn the camshaft timing gear against the camshaft and press harder after the pin enters the hole.

NOTICE:

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

Check that there is no clearance between the camshaft timing gear flange and camshaft.

Tighten the flange bolt while holding the camshaft.

Torque:

100 N*m{1020 kgf*cm, 74 ft.*lbf}

Check the lock of the camshaft timing gear.

1. Fix the camshaft in place and confirm that the camshaft timing gear is locked.
   

   NOTICE:

   Be careful not to damage the camshaft.

Release the lock pin.

1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.
   

   Text in Illustration

   *1	Advance Side Path
   *2	Retard Side Path
   *3	Open
   *4	Closed
   	Rubber
   	Vinyl Tape

   HINT:

   One of the 2 grooves on the cam journal is for retard side paths (upper) and the other is for advance side paths (lower). Each groove has 2 oil holes. Plug one of the oil holes in each groove with a piece of rubber as shown in the illustration before wrapping the cam journal with tape.

2. Prick a hole in the tape at the 2 oil holes not plugged with rubber pieces.
   





3. Apply compressed air at approximately 200 kPa (2.0 kgf/cm², 28 psi) to the two broken paths (the advance side path and the retard side path).
   

   Text in Illustration

   *1	Advance Side Path
   *2	Retard Side Path

   NOTICE:

   Cover the paths with a cloth to avoid oil splashing.





4. Confirm that the camshaft timing gear rotates in the advance direction when reducing the air pressure applied to the retard path.
   

   Text in Illustration

   *1	Advance Side Path
   *2	Retard Side Path
   *a	Hold Pressure
   *b	Decompress

   HINT:

   When the lock pin is released, the camshaft timing gear rotates in the advance direction.

5. When the camshaft timing gear comes to the most advanced position, release the air pressure from the retard side path, and then release the air pressure from the advance side path.
   

   NOTICE:

   The camshaft timing gear occasionally shifts to the retard side abruptly if air compression at the advanced side path is released first. This often results in the breakage of the lock pin.

Check for smooth rotation.

1. Except the position where the lock pin meets at the most retarded angle, turn the camshaft timing gear back and forth and check the movable range and that there is no disturbance.
   

   Standard:

   Moves smoothly in the range of about a 31° range
   

   NOTICE:

   Be sure to perform this check by hand, instead of with air pressure.

Check the lock in the most retarded position.

1. Confirm that the camshaft timing gear is locked at the most retarded position.
   

Remove the set bolt and camshaft timing gear.

NOTICE:

Be sure not to remove the other 3 bolts.

Align the mark link with the timing mark (2-dot mark) of the camshaft timing gear as shown in the illustration.

Apply new engine oil to the thrust portions and journals of the camshaft.

Temporarily put the chain on the No. 2 chain of the camshaft timing gear.

Align the knock pin hole of the camshaft timing gear with the knock pin of the No. 3 camshaft and insert the No. 3 camshaft into the camshaft timing gear.

Temporarily install the camshaft timing gear set bolt.

Set the No. 3 camshaft onto the cylinder head LH with the cam lobes of the No. 2 cylinder facing downward as shown in the illustration.

Set the 4 bearing caps in their proper locations.

Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

Using several steps, install the 8 bearing cap bolts uniformly in the sequence shown in the illustration.

Torque:

for 10 mm head bolt:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

for 12 mm head bolt:

24 N*m{245 kgf*cm, 18 ft.*lbf}

Text in Illustration

	10 mm Head Bolt
	12 mm Head Bolt

Set the paint mark of the chain between the timing marks of the camshaft timing gear.

Hold the hexagonal portion of the No. 3 camshaft with a wrench and tighten the camshaft timing gear set bolt.

Torque:

100 N*m{1020 kgf*cm, 74 ft.*lbf}

While pushing in the tensioner, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to fix the tensioner in place.

Temporarily install the camshaft timing sprocket and No. 3 chain tensioner with the bolt and align the mark links with the timing marks (1-dot mark and 2-dot mark) of the camshaft timing gear and sprocket.

Tighten the No. 3 chain tensioner bolt.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Align the knock pin hole of the camshaft timing sprocket with the knock pin of the No. 4 camshaft and insert the No. 4 camshaft into the camshaft timing sprocket.

Temporarily install the camshaft timing sprocket set bolt.

Set the 4 bearing caps in their proper locations.

Apply a light coat of engine oil to the threads of the bearing cap bolts.

Using several steps, install the 8 bearing cap bolts uniformly in the sequence shown in the illustration.

Torque:

for 10 mm head bolt:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

for 12 mm head bolt:

24 N*m{245 kgf*cm, 18 ft.*lbf}

Text in Illustration

	10 mm Head Bolt
	12 mm Head Bolt

Hold the hexagonal portion of the No. 4 camshaft with a wrench and tighten the camshaft timing sprocket set bolt.

Torque:

100 N*m{1020 kgf*cm, 74 ft.*lbf}

Remove the pin from the No. 3 chain tensioner

Release the chain tension between the camshaft timing gear (RH bank) and crankshaft timing gear by turning the crankshaft pulley clockwise slightly.

Text in Illustration

Slightly Turn

Align the mark link with the timing mark (1-dot mark) of the camshaft timing gear as shown in the illustration.

Apply new engine oil to the thrust portions and journals of the camshaft.

Temporarily put the chain on the No. 2 chain of the camshaft timing gear.

Align the knock pin hole of the camshaft timing gear with the knock pin of the camshaft and insert the camshaft into the camshaft timing gear.

Temporarily install the camshaft timing gear set bolt.

Set the camshaft onto the cylinder head RH with the cam lobes of the No. 1 cylinder facing downward as shown in the illustration.

Set the 4 bearing caps in their proper locations.

Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

Using several steps, install the 8 bearing cap bolts uniformly in the sequence shown in the illustration.

Torque:

for 10 mm head bolt:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

for 12 mm head bolt:

24 N*m{245 kgf*cm, 18 ft.*lbf}

Text in Illustration

	10 mm Head Bolt
	12 mm Head Bolt

Rotate the camshaft clockwise using a wrench so that the timing mark of the camshaft timing gear is aligned with the timing mark of the camshaft bearing cap.

Align the paint mark of the chain with the timing mark of the camshaft timing gear.

Hold the hexagonal portion of the camshaft with a wrench and tighten the camshaft timing gear set bolt.

Torque:

100 N*m{1020 kgf*cm, 74 ft.*lbf}

While pushing in the tensioner, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to fix the tensioner in place.

Temporarily install the camshaft timing sprocket and No. 2 chain tensioner with the bolt and align the mark links with the timing marks (1-dot mark) of the camshaft timing gear and sprocket.

Tighten the No. 2 chain tensioner bolt.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Set the No. 2 camshaft onto the cylinder head RH with the cam lobes of the No. 1 cylinder facing upward as shown in the illustration.

Set the 4 bearing caps in their proper locations.

Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

Using several steps, install the 8 bearing cap bolts uniformly in the sequence shown in the illustration.

Torque:

for 10 mm head bolt:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

for 12 mm head bolt:

24 N*m{245 kgf*cm, 18 ft.*lbf}

Text in Illustration

	10 mm Head Bolt
	12 mm Head Bolt

Rotate the No. 2 camshaft clockwise using a wrench so that the knock pin of the No. 2 camshaft is aligned with the knock pin hole of the camshaft timing sprocket.

Hold the hexagonal portion of the No. 2 camshaft with a wrench and install the camshaft timing sprocket set bolt.

Torque:

100 N*m{1020 kgf*cm, 74 ft.*lbf}

Remove the pin from the No. 2 chain tensioner.

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

While turning the stopper plate of the tensioner counterclockwise, insert a bar with a diameter of 3.5 mm (0.138 in.) into the holes in the stopper plate and tensioner to fix the stopper plate in place.

Install the No. 1 chain tensioner with the 2 bolts.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Remove the bar from the No. 1 chain tensioner.

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

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Turn the crankshaft pulley 2 complete revolutions slowly, and align the notch with the "0" timing mark of the timing chain cover.

Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing caps as shown in the illustration.

Turn the crankshaft pulley and align its groove with the "0" timing mark of the timing chain cover.

Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration.

Check the valves indicated in the illustration.

1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
   

   Standard Valve Clearance (Cold):

   Item	Specified Condition
   Intake	0.15 to 0.25 mm (0.00591 to 0.00984 in.)
   Exhaust	0.29 to 0.39 mm (0.0114 to 0.0154 in.)

   Text in Illustration

   *A	for Bank 1
   *B	for Bank 2
   *a	Exhaust Side
   *b	Intake Side
   	Engine Front

2. Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter.
   

Turn the crankshaft 2/3 of a revolution (240°).

Check the valves indicated in the illustration.

1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
   

   Standard Valve Clearance (Cold):

   Item	Specified Condition
   Intake	0.15 to 0.25 mm (0.00591 to 0.00984 in.)
   Exhaust	0.29 to 0.39 mm (0.0114 to 0.0154 in.)

   Text in Illustration

   *A	for Bank 1
   *B	for Bank 2
   *a	Exhaust Side
   *b	Intake Side
   	Engine Front

2. Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter.
   

Turn the crankshaft 2/3 of a revolution (240°).

Check the valves indicated in the illustration.

1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
   

   Standard Valve Clearance (Cold):

   Item	Specified Condition
   Intake	0.15 to 0.25 mm (0.00591 to 0.00984 in.)
   Exhaust	0.29 to 0.39 mm (0.0114 to 0.0154 in.)

   Text in Illustration

   *A	for Bank 1
   *B	for Bank 2
   *a	Exhaust Side
   *b	Intake Side
   	Engine Front

2. Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter.
   

Remove the camshaft (HILUX_TGN26 RM0000015D100CX.html).

Remove the 24 valve lifters from the cylinder head and cylinder head LH.

Determine the size of the valve lifter to be installed according to the following formulas or charts.

1. Using a micrometer, measure the thickness of the removed lifter.
   

2. Calculate the thickness of a new lifter so that the valve clearance is within the specified range.
   

   T:

   Thickness of removed lifter
   

   A:

   Measured valve clearance
   

   N:

   Thickness of new lifter
   

   Intake:

   N = T + (A - 0.20 mm (0.00787 in.))
   

   Exhaust:

   N = T + (A - 0.34 mm (0.0131 in.))
   





3. Select a new lifter with a thickness as close as possible to the calculated value.
   

   HINT:

   Lifters are available in 35 sizes in increments of 0.020 mm (0.000787 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).

   
   
   
   
   
   
   

   Text in Illustration

   *1	Valve Lifter Selection Chart (Intake)	*2	Measured Clearance mm (in.)
   *3	Installed Lifter Thickness mm (in.)	-	-

   Intake valve clearance (Cold):

   0.15 to 0.25 mm (0.00591 to 0.00984 in.)
   

   EXAMPLE:

   The 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0157 in.). Replace the 5.250 mm (0.2067 in.) lifter with a No. 46 lifter.
   

   
   

   New Lifter Thickness:

   
   

   Lifter No.	Thickness	Lifter No.	Thickness	Lifter No.	Thickness
   06	5.060 mm (0.1992 in.)	30	5.300 mm (0.2087 in.)	54	5.540 mm (0.2181 in.)
   08	5.080 mm (0.2000 in.)	32	5.320 mm (0.2094 in.)	56	5.560 mm (0.2189 in.)
   10	5.100 mm (0.2008 in.)	34	5.340 mm (0.2102 in.)	58	5.580 mm (0.2197 in.)
   12	5.120 mm (0.2016 in.)	36	5.360 mm (0.2110 in.)	60	5.600 mm (0.2205 in.)
   14	5.140 mm (0.2024 in.)	38	5.380 mm (0.2118 in.)	62	5.620 mm (0.2213 in.)
   16	5.160 mm (0.2031 in.)	40	5.400 mm (0.2126 in.)	64	5.640 mm (0.2220 in.)
   18	5.180 mm (0.2039 in.)	42	5.420 mm (0.2134 in.)	66	5.660 mm (0.2228 in.)
   20	5.200 mm (0.2047 in.)	44	5.440 mm (0.2142 in.)	68	5.680 mm (0.2236 in.)
   22	5.220 mm (0.2055 in.)	46	5.460 mm (0.2150 in.)	70	5.700 mm (0.2244 in.)
   24	5.240 mm (0.2063 in.)	48	5.480 mm (0.2157 in.)	72	5.720 mm (0.2252 in.)
   26	5.260 mm (0.2071 in.)	50	5.500 mm (0.2165 in.)	74	5.740 mm (0.2260 in.)
   28	5.280 mm (0.2079 in.)	52	5.520 mm (0.2173 in.)	-	-

   
   
   
   
   
   
   

   Text in Illustration

   *1	Valve Lifter Selection Chart (Exhaust)	*2	Measured Clearance mm (in.)
   *3	Installed Lifter Thickness mm (in.)	-	-

   Exhaust valve clearance (Cold):

   0.29 to 0.39 mm (0.0114 to 0.0154 in.)
   

   EXAMPLE:

   The 5.340 mm (0.210 in.) lifter is installed, and the measured clearance is 0.480 mm (0.0189 in.). Replace the 5.340 mm (0.210 in.) lifter with a No. 48 lifter.
   

   
   

   New Lifter Thickness:

   
   

   Lifter No.	Thickness	Lifter No.	Thickness	Lifter No.	Thickness
   06	5.060 mm (0.1992 in.)	30	5.300 mm (0.2087 in.)	54	5.540 mm (0.2181 in.)
   08	5.080 mm (0.2000 in.)	32	5.320 mm (0.2094 in.)	56	5.560 mm (0.2189 in.)
   10	5.100 mm (0.2008 in.)	34	5.340 mm (0.2102 in.)	58	5.580 mm (0.2197 in.)
   12	5.120 mm (0.2016 in.)	36	5.360 mm (0.2110 in.)	60	5.600 mm (0.2205 in.)
   14	5.140 mm (0.2024 in.)	38	5.380 mm (0.2118 in.)	62	5.620 mm (0.2213 in.)
   16	5.160 mm (0.2031 in.)	40	5.400 mm (0.2126 in.)	64	5.640 mm (0.2220 in.)
   18	5.180 mm (0.2039 in.)	42	5.420 mm (0.2134 in.)	66	5.660 mm (0.2228 in.)
   20	5.200 mm (0.2047 in.)	44	5.440 mm (0.2142 in.)	68	5.680 mm (0.2236 in.)
   22	5.220 mm (0.2055 in.)	46	5.460 mm (0.2150 in.)	70	5.700 mm (0.2244 in.)
   24	5.240 mm (0.2063 in.)	48	5.480 mm (0.2157 in.)	72	5.720 mm (0.2252 in.)
   26	5.260 mm (0.2071 in.)	50	5.500 mm (0.2165 in.)	74	5.740 mm (0.2260 in.)
   28	5.280 mm (0.2079 in.)	52	5.520 mm (0.2173 in.)	-	-

Install the camshaft (HILUX_TGN26 RM0000015CY00FX.html).

Check the valve clearance again.
If the result is not as specified, adjust the valve clearance.

Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.

Apply seal packing as shown in the illustration.

Seal packing:

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

Standard seal diameter:

2.0 to 3.0 mm (0.0787 to 0.118 in.)

NOTICE:

Install the cylinder head cover within 3 minutes after applying seal packing. After installing it, cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.

Install a new gasket to the cylinder head cover.

Install a new seal washers to the bolts.

Temporarily install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

Torque:

for bolt A:

10 N*m{102 kgf*cm, 7 ft.*lbf}

for bolt B and nut:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Text in Illustration

	Bolt A
	Bolt B
	Nut

Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.

Apply seal packing as shown in the illustration.

Seal packing:

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

Standard seal diameter:

2.0 to 3.0 mm (0.0787 to 0.118 in.)

NOTICE:

Install the cylinder head cover within 3 minutes after applying seal packing. After installing it, cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.

Install a new gasket to the cylinder head cover.

Install a new seal washers to the bolts.

Temporarily install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

Torque:

for bolt A:

10 N*m{102 kgf*cm, 7 ft.*lbf}

for bolt B and nut:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Text in Illustration

	Bolt A
	Bolt B
	Nut

Install the 6 ignition coils with the 6 bolts.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Connect the 6 ignition coil connectors.

Warm up the engine.

When using the intelligent tester:

1. Connect the intelligent tester to the DLC3.
   

2. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / IGN Advance.
   

3. Inspect the ignition timing during idling.
   

   Standard ignition timing:

   7 to 24° BTDC @ idle (transmission in neutral and A/C switch off)
   

4. Check that the ignition timing advances immediately when the engine speed is increased.
   

When not using the intelligent tester:

1. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.
   

   SST

   09843-18040
   

   Text in Illustration

   *a	Front view of DLC3

   NOTICE:

   Be sure not to improperly connect the terminals. This may damage the engine.

2. Connect the tester probe of a timing light to the wire of the ignition coil connector for the No. 1 cylinder.
   

   NOTICE:

   1. Use a timing light that detects primary signals.
      
   2. After the inspection, be sure to wrap the wire harness with tape.
      

3. Inspect the ignition timing during idling.
   

   Standard ignition timing:

   8 to 12° BTDC @ idle (transmission in neutral and A/C switch off)
   

4. Remove SST from the DLC3.
   

5. Inspect the ignition timing during idling.
   

   Standard ignition timing:

   7 to 24° BTDC @ idle (transmission in neutral and A/C switch off)
   

6. Disconnect the timing light from the engine.