Camshaft (For Sedan) Installation

Put the camshaft timing gear assembly and camshaft together with the straight pin of the groove.

Turn the camshaft timing gear assembly clockwise while pushing it gently toward the camshaft. When the pin fits the groove, push to ensure a good fit.

NOTICE:

Do not turn the camshaft timing gear in the retard direction (clockwise).

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

Tighten the flange bolt with the camshaft timing gear fixed.

Torque:

64 N*m{653 kgf*cm, 47 ft.*lbf}

NOTICE:

1. Do not lock the camshaft timing gear assembly when tightening the bolt.
   
2. Release the lock pin of the camshaft timing gear assembly first, and tighten the bolt when the lock pin is locked in the most retarded position.
   
3. Tightening the bolts with the lock pin locked could cause breakage of the lock pin.
   

Check that the camshaft timing gear assembly moves smoothly in the retard direction (clockwise) and is locked in the most retarded position.

Apply a light coat of engine oil to the camshaft and camshaft journals.

Install the chain onto the camshaft timing gear with the paint mark and the timing mark aligned as shown in the illustration.

Examine the front marks and numbers on No. 2 camshaft bearing cap and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts, in several steps, in the sequence shown in the illustration.

Torque:

13 N*m{129 kgf*cm, 9 ft.*lbf}

NOTICE:

Tighten each bolt uniformly while keeping the camshaft level.

Install No. 2 camshaft.

Hold the chain and align the timing mark on the camshaft timing sprocket with the paint mark of the chain.

Align the alignment pin hole in the camshaft timing sprocket with the alignment pin of the camshaft, and install the sprocket onto the camshaft.

Provisionally install the flange bolt.

Examine the front marks and numbers on camshaft bearing caps No. 1 and No. 2 and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts, in several steps, in the sequence shown in the illustration.

Torque:

for No. 2 bearing cap:

13 N*m{129 kgf*cm, 9 ft.*lbf}

for No. 1 bearing cap:

23 N*m{235 kgf*cm, 17 ft.*lbf}

NOTICE:

Tighten each bolt uniformly while keeping the camshaft level.

Using a wrench, hold the hexagonal lobe of camshaft No. 2 and install the flange bolt.

Torque:

64 N*m{653 kgf*cm, 47 ft.*lbf}

Remove the bar from the timing chain tensioner.

Turn the crankshaft damper and align its timing notch with the timing mark "0" of the oil pump.

Check that all the pairs of timing marks are aligned.

Apply adhesive to the end 2 or 3 threads of the screw plug.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent

Using an 8 mm hexagon wrench, install the screw plug.

Torque:

15 N*m{153 kgf*cm, 11 ft.*lbf}

Set the No. 1 cylinder to TDC/compression.

1. Turn the crankshaft damper and align its timing notch with the timing mark "0" of the oil pump.
   





2. Check that both timing marks on the camshaft timing sprocket and camshaft timing gear are facing upward, as shown in the illustration.
   

   HINT:

   If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

Check the valves indicated in the illustration.

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

   Valve clearance (cold):

   for intake:

   0.15 to 0.25 mm (0.006 to 0.010 in.)
   

   for exhaust:

   0.25 to 0.35 mm (0.010 to 0.014 in.)
   

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

Turn the crankshaft 1 complete revolution (360°) and align its timing notch with the timing mark "0" of the oil pump.

Check the valves indicated in the illustration.

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

   Valve clearance (cold):

   for intake:

   0.15 to 0.25 mm (0.006 to 0.010 in.)
   

   for exhaust:

   0.25 to0.35 mm (0.010 to 0.014 in.)
   

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

Remove the fan and generator V belt (YARIS_NCP93 RM000001DCJ016X_01_0002.html).

Remove the engine mounting insulator sub-assembly RH (YARIS_NCP93 RM000001DDZ00QX_01_0037.html).

Set the No. 1 cylinder to TDC/compression.

1. Turn the crankshaft damper and align its timing notch with the timing mark "0" of the oil pump.
   





2. Check that both timing marks on the camshaft timing sprocket and camshaft timing gear are facing upward, as shown in the illustration.
   

   HINT:

   If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

Place paint marks on the chain in the places where the timing marks of the camshaft timing sprocket and the camshaft timing gear are located.

Using an 8 mm hexagon wrench, remove the screw plug.

Insert a screwdriver into the service hole in the chain tensioner to pull the stopper plate of the chain tensioner upward.

Using a wrench, rotate No. 2 camshaft clockwise to push in the plunger of the chain tensioner.

Remove the screwdriver from the service hole, then align the hole in the stopper plate with the service hole and insert a 3 mm (0.12 in.) diameter bar into the holes to hold the stopper plate.

HINT:

1. Fix the stopper plate using the bar while rotating the camshaft right and left slightly.
   
2. Hold the bar with tape so that the bar does not come off.
   

Using a wrench, hold the hexagonal lobe of No. 2 camshaft and remove the fringe bolt.

Using several steps, loosen and remove the 11 bearing cap bolts uniformly in the sequence shown in the illustration, then remove No. 1 camshaft bearing cap and No. 2 camshaft bearing cap.

NOTICE:

Loosen each bolt uniformly while keeping the camshaft level.

Remove the fringe bolt and remove the camshaft timing sprocket.

Remove No. 2 camshaft.

Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence shown in the illustration, then remove No. 2 camshaft bearing cap.

NOTICE:

Loosen each bolt uniformly while keeping the camshaft level.

Hold the chain by hand and remove the camshaft and the camshaft timing gear assembly.

Tie the chain with a piece of string as shown in the illustration.

Remove the 16 valve lifters.

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

Calculate the thickness of a new lifter so that the valve clearance comes to within the specified values.

Valve clearance:

Intake A = B + (C - 0.20 mm (0.008 in.))

Exhaust A = B + (C - 0.30 mm (0.012 in.))

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

HINT:

Lifters are available in 35 sizes in increments of 0.020mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).

Intake valve clearance (cold):

0.15 to 0.25 mm (0.006 to 0.010 in.)

EXAMPLE:

A 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0158 in.). Replace the 5.250 mm (0.2067 in.) lifter with a new No. 46 lifter.

New Shim Thickness:

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

Exhaust valve clearance (Cold):

0.25 to 0.35 mm (0.010 to 0.014 in.)

EXAMPLE:

A 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.440 mm (0.0173 in.). Replace the 5.340 mm (0.2102 in.) lifter with a new No. 48 lifter.

New Shim Thickness:

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

Install the selected valve lifter.

Apply a light coat of engine oil to the camshaft and camshaft journals.

Install the chain onto the camshaft timing gear with the paint mark and the timing mark aligned as shown in the illustration.

Examine the front marks and the numbers on No. 2 camshaft bearing cap and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts in several steps in the sequence shown in the illustration.

Torque:

13 N*m{129 kgf*cm, 9 ft.*lbf}

NOTICE:

Tighten each bolt uniformly while keeping the camshaft level.

Install No. 2 camshaft.

Hold the chain, and align the timing mark on the camshaft timing sprocket with the paint mark of the chain.

Align the alignment pin hole in the camshaft timing sprocket with the alignment pin of the camshaft, and install the sprocket onto the camshaft.

Provisionally install the flange bolt.

Examine the front marks and the numbers of No. 1 camshaft bearing cap and No. 2 camshaft bearing cap and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts in several steps, in the sequence shown in the illustration.

Torque:

for No. 2 bearing cap:

13 N*m{129 kgf*cm, 9 ft.*lbf}

for No. 1 bearing cap:

23 N*m{235 kgf*cm, 17 ft.*lbf}

NOTICE:

Tighten each bolt uniformly while keeping the camshaft level.

Using a wrench, hold the hexagonal lobe of No. 2 camshaft and install the flange bolt.

Torque:

64 N*m{653 kgf*cm, 47 ft.*lbf}

Remove the bar from the timing chain tensioner.

Turn the crankshaft damper and align its timing notch with the timing mark "0" of the oil pump.

Check that all the pairs of timing marks are aligned.

Apply adhesive to the 2 or 3 threads of the screw plug.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent

Using an 8 mm hexagon wrench, install the screw plug.

Torque:

15 N*m{153 kgf*cm, 11 ft.*lbf}

Install the engine mounting insulator sub-assembly RH (YARIS_NCP93 RM000001DDV00RX_01_0047.html).

Install the fan and generator V belt (YARIS_NCP93 RM000001DCG017X_01_0001.html).

Adjust the fan and generator V belt (YARIS_NCP93 RM000001DCG017X_01_0002.html).

Inspect the fan and generator V belt (YARIS_NCP93 RM000001DCH00ZX_01_0001.html).

Install the engine mounting insulator sub-assembly RH with the 5 bolts and nut.

Torque:

52 N*m{530 kgf*cm, 38 ft.*lbf}

Provisionally install the fan and generator V belt onto each pulley.

NOTICE:

1. Make sure that there is no foreign matter or liquid, such as oil, on the belt and pulleys.
   
2. Make sure that the V belt is securely fitted into the rib grooves of the pulley.
   

Insert an adjusting bar between the engine mounting bracket and generator assembly. Pull the adjusting bar toward the vehicle front to adjust the generator V belt tension (YARIS_NCP93 RM000001DCH00ZX_01_0001.html).

NOTICE:

Do not insert the adjusting bar between the camshaft timing oil control valve assembly and generator assembly. It could damage the camshaft timing oil control valve assembly.

First tighten bolt A, then tighten bolt B.

Torque:

19 N*m{189 kgf*cm, 14 ft.*lbf} for bolt A

54 N*m{551 kgf*cm, 40 ft.*lbf} for bolt B

Check the belt for wear, cracks or other signs of damage.
If any of the following defects is found, replace the V-ribbed belt.

HINT:

1. The belt is cracked.
   
2. The belt is worn out to the extent that the wires are exposed.
   
3. The belt has chunks missing from the ribbed groves.
   

Check that the belt fits properly in the ribbed grooves.

HINT:

Check with your hand, to confirm that the belt has not slipped out of the grooves on the bottom to the pulley. If it has slipped out, replace the V-ribbed belt. Install a new V-ribbed belt correctly.

Inspect the V belt deflection and tension.

Deflection:

Item	Specified Condition
New belt	8.0 to 9.0 mm (0.31 to 0.35 in)
Used belt	12.5 to 13.5 mm (0.49 to 0.53 in)

Tension:

Item	Specified Condition
New belt	700 to 800 N (71 to 82 kg, 157 to 180 lb)
Used belt	300 to 400 N (31 to 41 kg, 67 to 90 lb)

HINT:

1. When inspecting the V belt deflection, apply 98 N (10 kgf) tensile force to it.
   
2. Perform the V belt inspection and adjustment while the engine is cold.
   
3. V-ribbed belt tension and deflection should be checked immediately after installation of a new belt, and after cranking the engine when inspecting a used belt.
   
4. Check the V belt deflection at the point between the specified pulleys where the deflection is greatest.
   
5. When installing a new belt, set its tension to the intermediate value of the specification.
   
6. When inspecting a belt which has been used for over 5 minutes, apply the Used Belt specifications.
   
7. When reinstalling a belt which has been used for over 5 minutes, adjust its deflection and tension to the intermediate values of each Used Belt specification.
   
8. V-ribbed belt tension and deflection should be checked after 2 revolutions of engine cranking.
   
9. When using a belt tension gauge, confirm its accuracy by using a master gauge first.
   

Install a new gasket to the cylinder head cover sub-assembly.

Apply seal packing to the cylinder head as shown in the illustration.

Seal Packing:

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

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the cylinder head cover sub-assembly within 3 minutes of applying the seal packing.
   
3. Do not start the engine for at least 2 hours after the installation.
   

Install the cylinder head cover sub-assembly with the 9 bolts, 2 nuts and 2 seal washers.

Tighten the 9 bolts and 2 nuts in the sequence shown in the illustration.

Torque:

10 N*m{102 kgf*cm, 7.0 ft.*lbf}

Install the wire harness bracket with the bolt.

Torque:

13 N*m{133 kgf*cm, 9.6 ft.*lbf}

Connect the connector and wire harness clamp shown in the illustration and connect the engine wire harness.

Connect the fuel injector connectors.

Connect fuel vapor feed hose assembly.

Connect the ventilation hose.

Install the 4 ignition coils with the 4 bolts.

Torque:

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

NOTICE:

If the body or cap of the ignition coil is dropped or subjected to a strong impact, replace the ignition coil with a new one.

Connect the 4 ignition coil connectors.

Tighten the 2 A nuts, then the 2 B nuts.

Torque:

7.0 N*m{71 kgf*cm, 62 in.*lbf}