Toyota 4Runner 2001-06

Camshaft, Bearings & Lifters 1

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Bearing Replacement



1gr-FE Engine

Remove the camshafts, then remove the No. 1 (bearing cap) and 2 (cylinder head) camshaft bearings. Clean the backside of the bearing (if not replacing with a new one) and bearing surface.

Align the bearing claw with the claw groove of the bearing cap and push in the No. 1 camshaft bearing. Install the camshaft bearing to the cylinder head. Reinstall the camshafts.

Click image to see an enlarged view

Fig. Align the bearing claw with the claw groove in the bearing cap (top) and install the No. 2 camshaft bearing to the cylinder head (bottom)-4.0L (1GR-FE) Engine

Inspection



Cam Height
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the camshafts.
  4.  
  5. Measure the cam height with a micrometer.
  6.  
  7. The intake camshaft should measure as follows:
    1. 3.4L (5VZ-FE) Engine: between 1.6657-1.6697 in. (42.310-42.410 mm) and not less than 1.6598 in. (42.160 mm).
    2.  
    3. 4.0L (1GR-FE) Engine: between 1.7389-1.7428 in. (44.168-44.268 mm) and not less than 1.7330 in. (44.018 mm).
    4.  
    5. 4.7L (2UZ-FE) Engine: between 1.6512-1.6551 in. (44.940-42.040 mm) and not less than 1.8262 in. (46.385 mm).
    6.  

  8.  
  9. The exhaust camshaft should measure as follows:
    1. 3.4L (5VZ-FE) Engine: between 1.6520-1.6559 in. (41.960-42.060 mm) and not less than 1.6461 in. (41.810 mm).
    2.  
    3. 4.0L (1GR-FE) Engine: between 1.7551-1.7591 inches (44.580-44.680 mm) and not less than 1.6453 inches (41.790 mm).
    4.  
    5. 4.7L (2UZ-FE) Engine: between 1.6520-1.6559 inches (44.960-42.060 mm) and not less than 1.6461 inches (41.810 mm).
    6.  

  10.  
  11. Camshaft should be replaced if it exceeds the limit.
  12.  

Camshaft Journal Clearance
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the camshafts from the vehicle.
  4.  
  5. Using a micrometer, measure the journal diameter.
  6.  
  7. Journal diameter should measure as follows:
    1. 3.4L (5VZ-FE) Engine: All journals between 1.0610-1.0616 in. (26.949-26.965 mm).
    2.  
    3. 4.0L (1GR-FE) Engine: No. 1 journal between 1.4162-1.4167 in. (35.971-35.985 mm). All other journals between 0.9039-0.9045 in. (22.959-22.975 mm).
    4.  
    5. 4.7L (2UZ-FE) Engine: All journals between 1.0612-1.0618 in. (26.954-26.970 mm).
    6.  

  8.  
  9. The camshaft should be replaced if it exceeds the limit.
  10.  

Camshaft Runout
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the camshafts.
  4.  
  5. Place the camshaft on a V-block, on a precise flat table.
  6.  
  7. Set the dial indicator to center journal.
  8.  
  9. Turn the camshaft to one direction by hand and measure the camshaft runout.
  10.  
  11. Runout should measure less than follows:
    1. 5VZ-FE and 4.0L (1GR-FE) Engines: 0.0024 in. (0.06 mm).
    2.  
    3. 4.7L (2UZ-FE) Engine: 0.0031 in. (0.08 mm).
    4.  

  12.  
  13. Camshaft should be replaced if it exceeds the limit.
  14.  

Removal & Installation



1gr-FE Engine
Left Side

Toyota identifies each camshaft by number: The right bank (passenger side) inner camshaft is No. 1, the right bank outer camshaft is No. 2. The left bank (driver-s side) inner camshaft shaft is No. 3 and the left bank outer camshaft is No. 4. Camshaft Nos. 1 and 3 are the intake camshafts. Nos. 2 and 4 are the exhaust camshafts.

The primary timing chain (large chain) is identified by Toyota as the No. 1 chain. The smaller chains that connect the camshaft sprockets are identified as the No. 2 chains.


WARNING
As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which are received the shaft thrust may crack or be damaged, causing the camshaft to seize or break.

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Remove the engine appearance cover.
  6.  
  7. Remove the air intake assembly.
  8.  
  9. Remove the upper intake manifold (air intake surge tank).
  10.  
  11. Remove the ignition coils.
  12.  
  13. Remove the valve covers.
  14.  
  15. Turn the crankshaft pulley, and align the notch with the timing mark -0- of the timing chain cover to set the No. 1 cylinder at Top Dead Center (TDC). Check that the timing marks of the camshaft timing gears (camshaft sprockets) are aligned with the timing marks of the bearing cap. Place paint marks on the No. 1 chain links that correspond with the timing marks of the camshaft timing gears.
  16.  
  17. Remove the timing chain cover plate and gasket to access the No. 1 timing chain tensioner. While turning the stopper plate of the tensioner upward, push in the plunger of the chain tensioner as shown in the illustration. While turning the stopper plate of the tensioner downward, insert a pin into the holes in the stopper plate and tensioner to fix the stopper plate. Remove the two bolts and chain tensioner.
  18.  
  19. While raising up the chain tensioner No. 2, insert a pin into the hole to secure it in the raised position.
  20.  
  21. Hold the hexagonal portion of the No. 4 camshaft with a wrench, and remove the camshaft timing gear set bolt. Separate the camshaft timing gear from the No. 4 camshaft.
  22.  
  23. Using several steps, loosen and remove the eight bearing cap bolts uniformly in the sequence. Remove the four bearing caps and No. 4 camshaft.
  24.  
  25. Remove the chain tensioner No. 3 bolt, and then remove the chain tensioner No. 3 and camshaft timing gear.

    Click image to see an enlarged view

    Fig. No.4 camshaft bearing cap bolt loosening sequence-4.0L (1GR-FE) Engine, left side

  26.  
  27. Release the chain tension between the camshaft timing gear (left bank) and crankshaft sprocket by turning the crankshaft pulley counterclockwise slightly.
  28.  
  29. Hold the hexagonal portion of the No. 3 camshaft with a wrench, and loosen the camshaft timing gear set bolt. Slide the camshaft timing gear forward and separate the No. 1 chain from the camshaft timing gear.
  30.  
  31. Using several steps, loosen and remove the eight bearing cap bolts uniformly in the sequence. Remove the 4 bearing caps.
  32.  
  33. Remove the camshaft timing gear set bolt with the No. 3 camshaft is lifted up, and then remove the No. 3 camshaft and camshaft timing gear w/ No. 2 chain. Tie the No. 1 chain up with string so it doesn-t fall into the timing chain cover.
  34.  

To install:

  1. Align the mark link (yellow) with the timing mark (1 dot mark) of the camshaft sprocket as shown in the illustration.
  2.  
  3. Apply new engine oil to the thrust portion and journal of the camshafts.
  4.  
  5. Temporarily put the No. 1 chain on the No. 2 chain of the camshaft timing gear.
  6.  
  7. Align the knock pin hole in 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.
  8.  
  9. Set the No. 3 camshaft onto the cylinder head with the cam lobes of the No. 2 cylinder faced downward as shown.
  10.  
  11. Install the 4 bearing caps in their proper locations. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Using several steps, install and tighten the eight bearing cap bolts uniformly in the sequence. Tighten the bolts with the 0.39 inch (10 mm) heads to 80 inch lbs. (9 Nm) and the bolts with the 0.47 inch (12 mm) heads to 18 ft. lbs. (24 Nm).

    Click image to see an enlarged view

    Fig. Place the camshaft on the head with the No.3 cylinder lobes facing downward as shown



    Click image to see an enlarged view

    Fig. No.3 camshaft bolt torque sequence-4.0L engine, left side

  12.  
  13. Align the paint mark of the No. 1 chain with the timing marks of the camshaft timing gear. Hold the hex portion of the camshaft with a wrench and tighten camshaft timing gear set bolt to 74 ft. lbs. (100 Nm).
  14.  
  15. Temporary install the camshaft timing gear and No. 2 chain tensioner. Align the marked links (yellow) with the timing marks (dot mark) of the camshaft timing gears. Tighten the chain tensioner mounting bolt to 14 ft. lbs. (19 Nm).
  16.  
  17. Align the knock pin hole in the camshaft timing gear with the knock pin of he No. 4 camshaft, and insert the No. 4 camshaft into the camshaft timing gear. Temporarily install the camshaft timing gear set bolt.
  18.  
  19. Install the 4 bearing caps in their proper locations. Apply a light coat of engine oil on the threads of the bearing cap bolts. Using several steps, install and tighten the eight bearing cap bolts uniformly in the sequence. Tighten the bolts with the 0.39 inch (10 mm) heads to 80 inch lbs. (9 Nm) and the bolts with the 0.47 inch (12 mm) heads to 18 ft. lbs. (24 Nm).
  20.  
  21. Hold the hex portion of the No. 4 camshaft with a wrench and tighten the camshaft timing gear set bolt to 74 ft. lbs. (100 Nm). Remove the pin from the chain tensioner.

    Click image to see an enlarged view

    Fig. No.4 camshaft bolt torque sequence-4.0L engine, left side

  22.  
  23. Release the chain tension between the camshaft timing gear (right bank) and crankshaft timing gear by turning the crankshaft pulley clockwise slightly.
  24.  

Remainder of the installation for both sides:

  1. Install the No. 1 chain tensioner and tighten the mounting bolts to 80 inch lbs. (9 Nm). Remove the pin from the chain tensioner. Install the cover plate with a new gasket and tighten to 80 inch lbs. (9 Nm).
  2.  
  3. Turn the crankshaft pulley 2 complete revolutions slowly, and align the notch with the timing mark -0- 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.
  4.  
  5. Inspect and adjust the valve clearance as necessary.
  6.  
  7. Install the valve covers.
  8.  
  9. Install the ignition coils.
  10.  
  11. Install the upper intake manifold.
  12.  
  13. Install the air intake assembly.
  14.  
  15. Install the engine appearance cover.
  16.  
  17. Refill the cooling system to the correct level.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Start the engine and check for leaks.
  22.  

Right Side

Toyota identifies each camshaft by number: The right bank (passenger side) inner camshaft is No. 1, the right bank outer camshaft is No. 2. The left bank (driver-s side) inner camshaft shaft is No. 3 and the left bank outer camshaft is No. 4. Camshaft Nos. 1 and 3 are the intake camshafts. Nos. 2 and 4 are the exhaust camshafts.

The primary timing chain (large chain) is identified by Toyota as the No. 1 chain. The smaller chains that connect the camshaft sprockets are identified as the No. 2 chains.


WARNING
As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which are received the shaft thrust may crack or be damaged, causing the camshaft to seize or break.

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Remove the engine appearance cover.
  6.  
  7. Remove the air intake assembly.
  8.  
  9. Remove the upper intake manifold (air intake surge tank).
  10.  
  11. Remove the ignition coils.
  12.  
  13. Remove the valve covers.
  14.  
  15. Turn the crankshaft pulley, and align the notch with the timing mark -0- of the timing chain cover to set the No. 1 cylinder at Top Dead Center (TDC). Check that the timing marks of the camshaft timing gears (camshaft sprockets) are aligned with the timing marks of the bearing cap. Place paint marks on the No. 1 chain links that correspond with the timing marks of the camshaft timing gears.
  16.  
  17. Remove the timing chain cover plate and gasket to access the No. 1 timing chain tensioner. While turning the stopper plate of the tensioner upward, push in the plunger of the chain tensioner as shown in the illustration. While turning the stopper plate of the tensioner downward, insert a pin into the holes in the stopper plate and tensioner to fix the stopper plate. Remove the two bolts and chain tensioner.
  18.  
  19. While raising up the chain tensioner No. 2, insert a pin into the hole to secure it in the raised position.
  20.  
  21. Hold the hexagonal portion of the No. 2 camshaft with a wrench, and remove the camshaft timing gear set bolt. Separate the camshaft timing gear from the No. 2 camshaft.
  22.  
  23. Rotate the camshaft counterclockwise using the wrench so that the cam lobes of No. 1 cylinder faces upward as shown in the illustration.
  24.  
  25. Using several steps, loosen and remove the eight bearing cap bolts uniformly in the sequence as shown in the illustration. Remove the four bearing caps and No. 2 camshaft.
  26.  
  27. Remove the chain tensioner No. 2 bolt, and then remove the chain tensioner No. 2 and camshaft timing gear.

    Click image to see an enlarged view

    Fig. Using paint, matchmark the chain links that correspond to the timing marks on the camshaft sprockets-4.0L (1GR-FE) Engine, right side



    Click image to see an enlarged view

    Fig. Remove the 4 bolts and the timing chain cover plate and gasket to access the No. 1 timing chain tensioner-4.0L (1GR-FE) Engine, right side



    Click image to see an enlarged view

    Fig. Rotate the No.2 camshaft counterclockwise so that the lobes for No.1 cylinder face upward-4.0L (1GR-FE) Engine, right side



    Click image to see an enlarged view

    Fig. No.2 camshaft cap bolt loosening sequence-4.0L (1GR-FE) Engine, right side

  28.  
  29. Remove the chain tensioner No. 2 bolt, and then remove the chain tensioner No. 2 and camshaft timing gear.
  30.  
  31. Hold the hexagonal portion of the No. 1 camshaft with a wrench, and loosen the camshaft timing gear set bolt. Slide the camshaft timing gear and separate the No. 1 chain from the camshaft timing gear.
  32.  
  33. Rotate the No. 1 camshaft counterclockwise using the wrench so that the cam lobes of No. 1 cylinder faces downward as shown in the illustration.
  34.  
  35. Using several steps, loosen and remove the 8 bearing cap bolts in the sequence as shown in the illustration. Remove the 4 bearing caps.
  36.  
  37. Remove the camshaft timing gear set bolt with the No. 1 camshaft is lifted up, and then remove the No. 1 camshaft and camshaft timing gear w/ No. 2 chain. Tie up the No. 1 chain with a string so it doesn-t fall into the timing chain cover.

    Click image to see an enlarged view

    Fig. Rotate the No.1 camshaft so the lobes for No.1 cylinder face downward-4.0L (1GR-FE) Engine, right side



    Click image to see an enlarged view

    Fig. Remove the no.1 camshaft bearing caps evenly and in several passes, in the sequence shown-4.0L engine, right side

  38.  

To install:

  1. Align the mark link (yellow) with the timing mark (1 dot mark) of the camshaft sprocket as shown in the illustration.
  2.  
  3. Apply new engine oil to the thrust portion and journal of the camshafts.
  4.  
  5. Temporarily put the No. 1 chain on the No. 2 chain of the camshaft timing gear.
  6.  
  7. Align the knock pin hole of the camshaft timing gear with the knock pin of the No. 1 camshaft, and insert the No. 1 camshaft into the camshaft timing gear. Temporarily install the camshaft timing gear set bolt.
  8.  
  9. Set the No. 1 camshaft onto the cylinder head with the cam lobes of the camshaft faced downward as before.
  10.  
  11. Install the 4 bearing caps in their proper locations. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Using several steps, install and tighten the eight bearing cap bolts uniformly in the sequence. Tighten the bolts with the 0.39 inch (10 mm) heads to 80 inch lbs. (9 Nm) and the bolts with the 0.47 inch (12 mm) heads to 18 ft. lbs. (24 Nm).

    Click image to see an enlarged view

    Fig. Painted link and timing mark alignment-4.0L (1GR-FE) Engine, right side



    Click image to see an enlarged view

    Fig. No.1 camshaft bolt torque sequence-4.0L (1GR-FE) Engine, right side

  12.  
  13. Rotate the No. 1 camshaft clockwise using the wrench so that the timing mark of the camshaft timing gear is aligned with the timing marks of the camshaft bearing cap. Align the paint mark of the No. 1 chain with the timing mark of the camshaft timing gear. Align the paint mark of the No. 1 chain with the timing mark of the camshaft timing gear.
  14.  
  15. Hold the hexagonal portion of the No. 1 camshaft with a wrench, then tighten the camshaft timing gear set bolt to 74 ft. lbs. (100 Nm).
  16.  
  17. Temporary install the camshaft timing gear and No. 2 chain tensioner. Align the marked links (yellow) with the timing marks (dot mark) of the camshaft timing gears. Tighten the chain tensioner mounting bolt to 14 ft. lbs. (19 Nm).

    Click image to see an enlarged view

    Fig. Rotate the No.1 camshaft clockwise so that the timing mark on the camshaft sprocket is aligned with the timing mark on the bearing cap-4.0L (1GR-FE) Engine, right side

  18.  
  19. Place the No.2 camshaft on the head with the No.1 cylinder lobes facing upwards, as before.
  20.  
  21. Install the four bearing caps in their proper locations. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Using several steps, install and tighten the eight bearing cap bolts uniformly in the sequence. Tighten the bolts with the 0.39 inch (10 mm) heads to 80 inch lbs. (9 Nm) and the bolts with the 0.47 inch (12 mm) heads to 18 ft. lbs. (24 Nm).
  22.  
  23. Rotate the No. 2 camshaft clockwise using the wrench so that the knock pin of the No. 2 camshaft is aligned with the knock pin hole of the camshaft timing gear. Install the camshaft timing gear set bolt, hold the No. 2 camshaft with the wrench and tighten the bolt to 74 ft. lbs. (100 Nm). Remove the pin from the No. 2 chain tensioner.

    Click image to see an enlarged view

    Fig. No.2 camshaft bolt torque sequence-4.0L (1GR-FE) Engine, right side

  24.  

2UZ-FE Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Remove the throttle body cover.
  6.  
  7. Disconnect the timing belt from the camshaft pulleys. Please see the timing belt procedure in this section. Use care when working around the timing belt. Do NOT allow anything to drop inside the timing belt cover. Do NOT allow the timing belt to come into contact with oil, water or dust.
  8.  
  9. Remove the camshaft timing pulleys. Please see the timing belt procedure in this section.
  10.  
  11. Remove the camshaft position sensor by removing the bolt and stud bolt and then removing the sensor.
  12.  
  13. If necessary, disconnect the power steering pump from the engine.
  14.  
  15. Remove the ignition coils.
  16.  
  17. Remove the three bolts and the stud bolt and remove the left side and right side timing belt rear plates.
  18.  
  19. Disconnect the fuel lines.
  20.  
  21. Tag for identification and detach the following electrical connectors:

    Throttle Position (TP) sensor
     
    Accelerator pedal position sensor connector
     
    Throttle control motor connector
     
    VSV connector for the EVAP system
     
    Eight fuel injector connectors
     
    Engine Coolant Temperature (ECT) sensor
     
    Water sender gauge connector
     
    Eight ignition coil connectors
     
    Two heated oxygen sensor connectors.
     

  22.  
  23. Tag for identification and disconnect the following hoses:

    The vacuum hose from the fuel pressure regulator.
     
    The PCV hose from the PCV valve on the left side cylinder head.
     
    The EVAP hose from the charcoal canister from the VSV for the EVAP system.
     
    The EVAP hose from the charcoal canister from the EVAP pipe on the intake manifold.
     
    The power steering vacuum switch lines from the intake manifold.
     
    The brake booster vacuum line.
     

  24.  
  25. Remove the upper and lower intake manifolds.
  26.  
  27. Remove the 18 bolts and seal washers from the cylinder head covers and remove the covers and gaskets. If necessary, remove semi-circular plugs and camshaft housing plugs.
    WARNING
    Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

  28.  
  29. Remove the camshafts using the following procedure.
    1. Check the crankshaft pulley position. Check that the timing mark of the crankshaft pulley is aligned with the centers of the crankshaft pulley bolt and the idler pulley.
      WARNING
      Having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you remove the camshaft, causing damage. Always set the crankshaft pulley at the correct angle.

    2.  
    3. Remove the right side camshafts. Bring the service bolt hole of the sub-gear upward by turning the hexagon wrench portion of the exhaust camshaft with a wrench. Secure the sub-gear to the main gear with a bolt 6mm in diameter x 1.0mm thread pitch x 16-20mm long.
      WARNING
      When removing the camshafts, make sure that the torsion spring force of the sub-gear has been eliminated by the above operation.

    4.  
    5. Set the timing mark (one dot mark) of the camshaft main gear at an angle approximately 10° above horizontal by turning the hexagon wrench portion of the exhaust camshaft with a wrench.
    6.  
    7. Uniformly loosen and remove the 22 bearing cap bolts in several passes, in the sequence illustrated.
    8.  
    9. Remove the oil feed pipe, the bearing caps and the camshafts.
    10.  
    11. Remove the left side camshafts. Bring the service bolt hole of the sub-gear upward by turning the hexagon wrench portion of the exhaust camshaft with a wrench. Secure the sub-gear to the main gear with a bolt 6mm in diameter x 1.0mm thread pitch x 16-20mm long.
      WARNING
      When removing the camshafts, make sure that the torsion spring force of the sub-gear has been eliminated by the above operation.

    12.  
    13. Align timing marks (two dot marks) of the camshaft drive gear by turning the hexagon wrench portion of the exhaust camshaft with a wrench.
    14.  
    15. Uniformly loosen and remove the 22 bearing cap bolts in several passes, in the sequence illustrated. Note that there are five different length bearing cap bolts that, at assembly, MUST be returned to their proper locations. Mark these bolts or place in holes punched through cardboard to make sure they will be in the proper location and sequence. Take the time to accurately measure each bolt and mark its length on the cardboard. The reason for this is that at assembly, certain lengths of bolts are handled differently, and they are identified by length.
    16.  
    17. Remove the oil feed pipe, the bearing caps and the camshafts.
      NOTE
      Use care to keep the bearing caps in order, in the exact same sequence and direction as originally installed on the engine.



      Click image to see an enlarged view

      Fig. Cylinder heads, camshafts and related components-4.7L (2UZ-FE) Engine



      Click image to see an enlarged view

      Fig. Setting up the engine and aligning the timing marks before right side camshaft removal. Note the 6mm bolt used to lock together the two-piece cam gear-4.7L (2UZ-FE) Engine



      Click image to see an enlarged view

      Fig. Setting up the engine and aligning the timing marks before left side camshaft removal. Note the 6mm service bolt used to lock together the two-piece cam gear-4.7L (2UZ-FE) Engine



      Click image to see an enlarged view

      Fig. Use this sequence to loosen the camshaft bearing cap bolts: top-Left Side Bank; Bottom-Right Side Bank-4.7L (2UZ-FE) Engine



      Click image to see an enlarged view

      Fig. When installing the right side camshafts, align the timing marks as shown and apply sealer to the front bearing cap where indicated-4.7L (2UZ-FE) Engine



      Click image to see an enlarged view

      Fig. When installing the left side camshafts, align the timing marks as shown and apply sealer to the front bearing cap where indicated-4.7L (2UZ-FE) Engine



      Click image to see an enlarged view

      Fig. After the camshaft front bearing caps are set in place, but before the bolts are final-tightened, push in new oil seals-4.7L (2UZ-FE) Engine



      Click image to see an enlarged view

      Fig. Make sure the camshaft bearing caps are properly identified and correctly installed. Verify the proper length bolt is installed in the correct location, then tighten in the sequence shown-4.7L (2UZ-FE) Engine, right side bank shown



      Click image to see an enlarged view

      Fig. Make sure the camshaft bearing caps are properly identified and correctly installed. Verify the proper length bolt is installed in the correct location, then tighten in the sequence shown-4.7L (2UZ-FE) Engine, left side bank shown

    18.  

  30.  

To install:

  1. If disassembled, assemble the exhaust camshafts and sprockets using the following procedure:
    1. Install the camshaft gear spring, camshaft sub-gear and wave washer. Attach the pins on the gears to the gear spring ends.
    2.  
    3. Install the snapring.
    4.  
    5. Mount the hexagon wrench head portion of the camshaft in a vise. Use care not to damage the camshaft.
    6.  
    7. Using Toyota-s Special Service tool, or a suitable pin-type spanner, align the holes of the camshaft main gear and sub-gear by turning the camshaft sub-gear counterclockwise, and temporarily install a bolt 6mm in diameter x 1.0mm thread pitch x 16-20mm long. Make sure the teeth of the gears are aligned, and then tighten the bolt to secure the assembly.
    8.  

  2.  
  3. Remove any old sealer from the semi-circular camshaft housing plugs. Apply fresh sealer to the plug grooves and install the camshaft housing plugs to the cylinder heads.
    WARNING
    Since 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 head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

  4.  
  5. Install the right side camshafts using the following procedure:
    1. Apply engine assembly lube or multipurpose grease to the thrust portion of the intake and exhaust camshafts.
    2.  
    3. Lay the intake and exhaust camshafts carefully in position.
    4.  
    5. Set the timing mark (one dot mark) of the camshaft main gear at an angle approximately 10° above horizontal by turning the hexagon wrench portion of the exhaust camshaft with a wrench.
    6.  
    7. Remove any old sealer from the front bearing cap. Apply a bead of fresh sealer approximately 1 / 16 inch in diameter, to the areas indicated in the illustration. Use care to keep sealer out of the front bearing cap grooves. Assemble the front bearing cap before the sealer has a chance to skin-over (start to cure). Note that installing the front bearing cap will determine the thrust clearance of the camshaft.
    8.  
    9. Install the other bearing caps in the sequence illustrated with the arrow mark facing forward. Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap.
    10.  
    11. Install a new camshaft oil seal.
    12.  
    13. Apply a light coat of engine oil on the threads of only two sizes (the two longest) of camshaft bearing cap bolts. These bolts are:

      The 2.83 inch (72mm) bolts (called bolt -D-).
       
      The 3.70 inch (94mm) bolts (called bolt -E-).
       

    14.  
    15. Do NOT apply engine oil under the heads of the remaining camshaft bearing cap bolts. These bolts are:

      The 0.98 inch (25mm) bolts (called bolt -A-).
       
      The 1.50 inch (38mm) bolts (called bolt -B-).
       
      The 2.05 inch (52mm) bolts (called bolt -C-).
       

    16.  

  6.  
  7. Uniformly tighten the 22 bearing cap bolts in several passes, in the sequence illustrated:
    1. Torque the shortest bolts (bolt -A-) to 69 inch lbs. (7.5 Nm).
    2.  
    3. Torque all other bolts to 144 inch lbs. (16 Nm).
    4.  
    5. Bring the service bolt hole of the sub-gear upward by turning the hexagon wrench portion of the exhaust camshaft with a wrench. Remove the bolt. This allows the torsion spring and sub-gear to remove gear backlash.
    6.  

  8.  
  9. Install the left side camshafts using the same procedure.
  10.  
  11. Turn the camshaft(s) and position so the lobes are upward, and check and adjust the valve clearance, noting the following:
    1. Turn the crankshaft pulley and align its groove with the timing mark 0 on the No. 1 timing belt cover.
    2.  
    3. Install the timing belt rear plates.
    4.  
    5. Check that the timing marks of the camshaft timing pulleys and the timing belt rear plates are aligned. If not, turn the crankshaft exactly one revolution (360°) and align the marks.
    6.  
    7. Using a feeler gauge, measure the distance between the valve lifter and camshaft. Clearance should be 0.006-0.010 inch (0.15-0.25mm) on the intake camshaft and 0.010-0.014 inch (0.25-0.35mm) on the exhaust camshaft.
    8.  

  12.  
  13. Clean all old sealer from the four semi-circular camshaft plugs. Apply a fresh bead of sealer to the center groove of the plugs and install the plugs to the cylinder head.
  14.  
  15. Clean all old sealer from the cylinder head covers. Apply fresh sealer at the joint where the camshaft front bearing cap meets the cylinder head cover sealing surface. Use new cylinder head cover gaskets. Make sure the seal washers under the bolt heads are in good condition. Install the cylinder head covers. Uniformly tighten the bolts in several passes with final torque to 53 inch lbs. (6 Nm).
  16.  
  17. Install the upper and lower intake manifolds using the procedures found in this section. Use care to make sure the lower intake manifold gaskets are properly installed. Factory replacement gaskets should have white paint marks which should be facing upward. Align the port holes of the gasket and the cylinder head.
  18.  
  19. Using the identification tags made at disassembly, connect the following hoses to the intake manifold:

    Vacuum hose to the fuel pressure regulator.
     
    PCV hose to the PCV valve on the left side cylinder head.
     
    EVAP hose to the charcoal canister from the VSV for the EVAP system.
     
    EVAP hose to the charcoal canister from the EVAP pipe on the intake manifold.
     
    Power steering vacuum switch lines to the intake manifold.
     
    Brake booster vacuum line.
     

  20.  
  21. Using the identification tags made at disassembly, attach the following electrical connectors:

    Throttle Position (TP) sensor
     
    Accelerator pedal position sensor connector
     
    Throttle control motor connector
     
    VSV connector for the EVAP system
     
    Eight fuel injector connectors
     
    Engine Coolant Temperature (ECT) sensor
     
    Water sender gauge connector
     
    Eight ignition coil connectors
     
    Two heated oxygen sensor connectors
     

  22.  
  23. Connect the fuel lines.
  24.  
  25. If not done so earlier, install the timing belt rear plates and tighten the bolts to 66 inch lbs. (7.5 Nm).
  26.  
  27. Install the throttle body.
  28.  
  29. Install the ignition coils to their proper spark plug.
  30.  
  31. Install the automatic transmission fluid dipstick and fill tube.
  32.  
  33. Connect the front exhaust pipe.
  34.  
  35. Install the power steering pump.
  36.  
  37. Install the camshaft position sensor.
  38.  
  39. Install the camshaft timing pulleys and the timing belt.
  40.  
  41. An oil and filter change is recommended.
  42.  
  43. Refill the engine with coolant.
  44.  
  45. Start the engine and check for leaks.
  46.  

 
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