2UZ-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION (2008 Sequoia)

Last Modified: 11-29-2007		1.6 A
Service Category: Engine/Hybrid System	Section: Engine Mechanical
Model Year: 2008	Model: Sequoia	Doc ID: RM000002WGD007X
Title: 2UZ-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION (2008 Sequoia)

INSTALLATION

1. INSTALL CAMSHAFT SETTING OIL SEAL

(a) Apply MP grease to the lip of a new oil seal.

NOTICE:

Do not allow foreign matter to contact the lip of the oil seal.
Do not allow MP grease to contact the dust seal.

(b) Insert 2 new oil seals into the camshaft timing tube until they reach the stopper.

NOTICE:

Be careful of the installation direction.
Do not turn over the lip of the oil seal.

2. INSTALL CAMSHAFT TIMING TUBE ASSEMBLY

(a) Align the timing tube knock pin with the knock pin groove of the drive gear, and temporarily install the drive gear with the 4 bolts.

(b) Using SST and a 5 mm hexagon wrench, uniformly tighten the 4 bolts in several steps.

SST: 09960-10010

09962-01000

09963-00500

Torque: 7.5 N·m (76 kgf·cm, 66 in·lbf)

NOTICE:

Be careful not to damage the timing tube.

NOTICE:

Be careful not to damage the camshaft.

(d) Align the camshaft knock pin with the knock pin groove of the timing tube, and push the timing tube by hand until it touches the bottom.

NOTICE:

Do not forcefully push on the camshaft timing tube. This may cause the camshaft knock pin tip to damage the installation surface of the camshaft timing tube.

(e) Using a 10 mm hexagon wrench, install the bolt.

Torque: 78 N·m (795 kgf·cm, 58 ft·lbf)

(f) Install the seal washer and screw plug.

Torque: 15 N·m (153 kgf·cm, 11 ft·lbf)

3. INSTALL NO. 3 CAMSHAFT SUB GEAR

(a) Install the gear spring, sub-gear and wave washer.

HINT:

Attach the pins on the gears to the gear spring ends.

(b) Using snap ring pliers, install the snap ring.

NOTICE:

Be careful not to damage the camshaft.

(d) Using SST, align the holes of the driven gear and sub-gear by turning the sub-gear clockwise, and temporarily install a service bolt.

Recommended Service Bolt:

Thread Diameter	Thread Pitch	Bolt Length
6 mm	1.0 mm	16 to 20 mm (0.630 to 0.787 in.)

(e) Align the gear teeth of the driven gear and sub-gear, and tighten the service bolt.

4. INSTALL CAMSHAFT SUB-ASSEMBLY (for Bank 1)

NOTICE:

As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged. To avoid this, the following steps should be carried out.

HINT:

When performing this procedure to adjust the valve clearance, it is not necessary to apply seal packing to the No. 5 bearing cap and camshaft housing plug.

(a) Check that the timing mark of the crankshaft timing pulley is in the position shown in the illustration, and that the piston is below the TDC of compression.

NOTICE:

Having the crankshaft pulley at a wrong angle can cause the piston head and valve head to come into contact with each other when removing the camshaft. Always set the crankshaft pulley at the correct angle as shown in the illustration.

(b) Apply a light coat of engine oil to the cam lobe and gear of the camshaft and also the journal of the cylinder head.

(c) Using a wrench, align the timing marks (2 dot marks each) of the camshaft drive and driven main gears, and set the No. 3 and No. 4 camshafts in place.

(d) Install the bearing cap.

(1) Apply seal packing to the camshaft housing plug groove.

HINT:

Remove any old packing (FIPG) material before applying new seal packing.

Seal packing:

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

(2) Install the camshaft housing plug and oil control valve filter to the cylinder head as shown in the illustration.

NOTICE:

Be careful of the installation direction.

Remove any oil from the contact surface.

(3) Apply seal packing to the No. 1 bearing cap as shown in the illustration.

Seal packing:

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

Standard seal diameter:

1.5 to 2.0 mm (0.0591 to 0.0787 in.)

NOTICE:

Do not apply seal packing to the front bearing cap grooves.

Install the No. 1 bearing cap and housing plug within 3 minutes.

(4) Install 4 new seal washers to the bearing cap bolts (A and B).

(5) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts (C to E).

NOTICE:

Do not apply engine oil to the bearing cap bolts (A and B).

(6) Temporarily install the oil feed pipe and bearing caps with the 22 bolts, as shown in the illustration.

Bolt Length:

Item	Length
Bolt A with seal washer	94 mm (3.70 in.)
Bolt B with seal washer	72 mm (2.84 in.)
Bolt C	25 mm (0.984 in.)
Bolt D	55 mm (2.17 in.)
Bolt E	40 mm (1.58 in.)

(7) Push in the camshaft setting oil seal.

(8) Uniformly tighten the 22 bearing cap bolts in several steps, in the sequence shown in the illustration.

for bolt 21, 22

Torque: 7.5 N·m (76 kgf·cm, 66 in·lbf)

for other bolt

Torque: 16 N·m (163 kgf·cm, 12 ft·lbf)

(e) Bring the service bolt installed in the driven sub-gear upward by turning the hexagonal portion of the camshaft with a wrench.

(f) Remove the service bolt.

5. INSTALL REAR TIMING BELT PLATE LH

(a) Install the No. 1 timing belt plate and No. 2 timing plate with the 3 bolts.

Torque: 7.5 N·m (76 kgf·cm, 66 in·lbf)

6. INSTALL CAMSHAFT TIMING PULLEY SUB-ASSEMBLY LH

(a) Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.

(b) Temporarily install the 4 bolts of the camshaft timing pulley.

(d) Using a 5 mm hexagon wrench, tighten the 4 bolts.

Torque: 8.1 N·m (83 kgf·cm, 72 in·lbf)

7. INSTALL CAMSHAFT POSITION SENSOR ASSEMBLY

8. INSTALL CAMSHAFT (for Bank 2)

NOTICE:

HINT:

When performing this procedure to adjust the valve clearance, it is not necessary to apply seal packing to the No. 5 bearing cap and camshaft housing plug.

(a) Check that the timing mark of the crankshaft timing pulley is in the position shown in the illustration, and that the piston is below the TDC of compression.

NOTICE:

(b) Apply a light coat of engine oil to the cam lobe and gear of the camshaft and also the journal of the cylinder head.

(c) Using a wrench, align the timing marks (1 dot marks each) of the camshaft drive and driven main gears, and set the No. 1 and No. 2 camshafts in place.

(d) Install the bearing cap.

(1) Apply seal packing to the camshaft housing plug groove.

Seal packing:

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

HINT:

Remove any old packing (FIPG) material before applying new seal packing.

(2) Install the camshaft housing plug and oil control valve filter to the cylinder head as shown in the illustration.

NOTICE:

Be careful of the installation direction.

Remove any oil from the contact surface.

(3) Apply seal packing to the No. 1 bearing cap as shown in the illustration.

Seal packing:

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

Standard seal diameter:

1.5 to 2.0 mm (0.0591 to 0.0787 in.)

NOTICE:

Do not apply seal packing to the front bearing cap grooves.

Install the No. 1 bearing cap and housing plug within 3 minutes.

(4) Install 4 new seal washers to the bearing cap bolts (A and B).

(5) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts (C to E).

NOTICE:

Do not apply engine oil to the bearing cap bolts (A and B).

(6) Temporarily install the oil feed pipe and bearing caps with the 22 bolts, as shown in the illustration.

Bolt Length:

Item	Length
Bolt A with seal washer	94 mm (3.70 in.)
Bolt B with seal washer	72 mm (2.84 in.)
Bolt C	25 mm (0.984 in.)
Bolt D	55 mm (2.17 in.)
Bolt E	40 mm (1.58 in.)

(7) Push in the camshaft setting oil seal.

(8) Uniformly tighten the 22 bearing cap bolts in several steps, in the sequence shown in the illustration.

for bolt 21, 22

Torque: 7.5 N·m (76 kgf·cm, 66 in·lbf)

for other bolt

Torque: 16 N·m (163 kgf·cm, 12 ft·lbf)

(e) Bring the service bolt installed in the driven sub-gear upward by turning the hexagonal portion of the camshaft with a wrench.

(f) Remove the service bolt.

9. INSTALL REAR TIMING BELT PLATE RH

(a) Install the No. 1 timing belt plate and No. 2 timing belt plate with the 4 bolts.

Torque: 7.5 N·m (76 kgf·cm, 66 in·lbf)

10. INSTALL CAMSHAFT TIMING PULLEY

(a) Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.

(b) Temporarily install the 4 bolts of the camshaft timing pulley.

(d) Using a 5 mm hexagon wrench, tighten the 4 bolts.

Torque: 8.1 N·m (83 kgf·cm, 72 ft·lbf)

11. INSTALL TIMING BELT

12. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

13. INSPECT VALVE CLEARANCE

14. ADJUST VALVE CLEARANCE

15. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

(a) Apply seal packing to the semicircular plug grooves.

Seal packing:

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

(b) Install the 2 semicircular plugs to the cylinder heads.

(d) 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:

Remove any oil from the contact surface.

Install the cylinder head cover within 3 minutes after applying seal packing.

(e) Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several steps.

Torque: 10 N·m (102 kgf·cm, 7 ft·lbf)

16. INSTALL VENTILATION HOSE

(a) Install the ventilation hose.

17. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Apply seal packing to the semicircular plug grooves.

Seal packing:

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

(b) Install the 2 semicircular plugs to the cylinder heads.

(d) 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:

Remove any oil from the contact surface.

Install the cylinder head cover within 3 minutes after applying seal packing.

(e) Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several steps.

Torque: 10 N·m (102 kgf·cm, 7 ft·lbf)

18. INSTALL SPARK PLUG

19. INSTALL IGNITION COIL ASSEMBLY

20. INSTALL NO. 1 WATER PIPE SUB-ASSEMBLY

21. CONNECT INLET HEATER WATER HOSE D

(a) Connect the inlet heater water hose D to the No. 3 water by-pass pipe.

22. CONNECT NO. 5 WATER BY-PASS HOSE

(a) Connect the No. 5 water by-pass hose to the No. 3 water by-pass pipe.

23. INSTALL ENGINE WIRE

(a) Connect the 3 connectors to the engine room junction block.

(b) Install the engine wire with the nut.

Torque: 10 N·m (102 kgf·cm, 7 ft·lbf)

(d) Install the ground wire with the bolt.

Torque: 8.0 N·m (82 kgf·cm, 71 in·lbf)

(e) Connect the positive (+) battery terminal and install the engine wire with the nut.

Torque: 13 N·m (133 kgf·cm, 10 ft·lbf)

24. INSTALL AIR SWITCHING VALVE ASSEMBLY (for Bank 1)

(a) Install the air switching valve assembly .

25. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY

26. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY

27. CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY

28. INSTALL FUEL PIPE CLAMP

29. INSTALL VACUUM HOSE ASSEMBLY

30. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

31. INSTALL NO. 1 TIMING BELT COVER

32. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY

33. INSTALL FAN BRACKET SUB-ASSEMBLY

34. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

35. INSTALL NO. 2 TIMING BELT COVER SUB-ASSEMBLY

36. INSTALL NO. 3 TIMING BELT COVER SUB-ASSEMBLY LH

37. INSTALL NO. 2 TIMING CHAIN OR BELT COVER

38. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

39. INSTALL OIL COOLER PIPE

40. INSTALL COOLER COMPRESSOR ASSEMBLY

41. INSTALL GENERATOR ASSEMBLY

42. INSTALL VANE PUMP ASSEMBLY

43. INSTALL FAN SHROUD (w/ Trailer Towing System)

44. INSTALL FAN SHROUD (w/o Trailer Towing System)

45. CONNECT OUTLET RADIATOR HOSE

46. CONNECT INLET RADIATOR HOSE

47. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE

48. INSTALL THROTTLE BODY COVER SUB-ASSEMBLY

49. ADD ENGINE OIL

50. ADD ENGINE COOLANT

51. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque: 5.4 N·m (55 kgf·cm, 48 in·lbf)

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected .

52. INSPECT FOR OIL LEAK

53. INSPECT FOR COOLANT LEAK

54. INSPECT FOR FUEL LEAK

55. CHECK ENGINE OIL LEVEL

56. INSPECT IGNITION TIMING

57. INSPECT ENGINE IDLE SPEED

58. INSTALL NO. 1 ENGINE UNDER COVER