Toyota 2AR-FE Engine Camshaft Installation Guide
This guide provides detailed instructions for the installation of the camshaft on the Toyota 2AR-FE engine, specifically for the 2010 model year RAV4 (production range 08/2009 onwards). It covers steps from bearing installation to final checks.
INSTALLATION
1. INSTALL NO. 2 CAMSHAFT BEARING
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2. INSTALL NO. 1 CAMSHAFT BEARING
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3. INSTALL OIL CONTROL VALVE FILTER
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4. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
(a) Align and attach the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear assembly.
Text in Illustration:
- *1: Knock Pin Hole
- *2: Knock Pin
Illustration Description: Shows a camshaft timing exhaust gear with a designated pin hole (*1) and a corresponding knock pin (*2) on the camshaft.
(b) Check that there is no clearance between the camshaft timing exhaust gear assembly and camshaft flange.
Text in Illustration:
| Label | Description |
|---|---|
| *1 | Camshaft Timing Exhaust Gear |
| *2 | Clearance |
| *3 | Camshaft Flange |
| *a | INCORRECT |
| *b | CORRECT |
| *c | No Clearance |
Illustration Description: Two views are shown. The first view depicts an incorrect installation where there is clearance (*2) between the camshaft timing exhaust gear (*1) and the camshaft flange (*3). The second view shows the correct installation with no clearance (*c), labeled CORRECT (*b). The incorrect state is labeled INCORRECT (*a).
(c) Fix the camshaft timing exhaust gear assembly with the bolt.
Torque: 85 N·m {867 kgf·cm, 63ft·lbf}
NOTICE: Do not disassemble the camshaft timing exhaust gear.
Illustration Description: Shows the camshaft timing exhaust gear assembly being secured with a bolt.
5. SET TDC/COMPRESSION
(a) Turn the crankshaft pulley until its timing notch (groove) and the timing mark "0" of the timing chain cover are aligned.
Text in Illustration:
- *1: Timing Notch
Illustration Description: Shows the crankshaft pulley with its timing notch (groove) aligned with the timing mark "0" on the timing chain cover.
6. INSTALL NO. 2 CAMSHAFT
(a) Make sure that the valve rocker arms are installed as shown in the illustration.
Text in Illustration:
| Label | Description |
|---|---|
| *1 | Valve Rocker Arm |
| *2 | Valve Lash Adjuster |
| *3 | Valve Stem Cap |
Illustration Description: Depicts the valve rocker arms (*1), valve lash adjusters (*2), and valve stem caps (*3) correctly positioned on the camshaft.
(b) Clean the camshaft journals.
(c) Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.
(d) Hold up the chain and align the matchmark and the paint mark and install the camshaft.
Text in Illustration:
- *1: Paint Mark
- *2: Matchmark
Illustration Description: Shows the camshaft being installed, aligning a paint mark (*1) on the gear and a matchmark (*2) on the chain.
7. INSTALL CAMSHAFT
(a) Make sure that the valve rocker arms are installed as shown in the illustration.
Text in Illustration:
- *1: Valve Rocker Arm
- *2: Valve Lash Adjuster
- *3: Valve Stem Cap
Illustration Description: Similar to step 6(a), this shows the valve rocker arms (*1), valve lash adjusters (*2), and valve stem caps (*3) correctly positioned.
(b) Clean the camshaft journals.
(c) Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.
(d) Install the camshaft to the camshaft housing as shown in the illustration.
Text in Illustration:
- *1: Knock Pin
- *a: Approximately 17°
Illustration Description: Shows the camshaft being installed into its housing, aligning a knock pin (*1) and indicating an approximate angle of 17° (*a).
8. INSTALL CAMSHAFT BEARING CAP
(a) Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.
Illustration Description: Shows camshaft bearing caps labeled with numbers (1 through 5) and various marks, indicating their correct placement.
(b) Using several steps, uniformly tighten the 10 bolts in the sequence shown in the illustration.
Torque: 27 N·m {275 kgf·cm, 20ft·lbf}
Illustration Description: Depicts the sequence (numbered 1 through 10) for uniformly tightening the 10 bolts securing the camshaft bearing caps.
(c) Using several steps, uniformly tighten the 11 bolts in the sequence shown in the illustration.
Torque: 16 N·m {163 kgf·cm, 12ft·lbf}
Illustration Description: Shows the sequence (numbered 1 through 11) for uniformly tightening 11 bolts, likely for another set of bearing caps or a related component.
(d) Check the torque of each bolt again.
9. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
(a) Check the camshaft timing gear position.
Text in Illustration:
| Label | Description |
|---|---|
| *1 | Knock Pin Hole |
| *2 | Alignment Mark |
| *a | Advanced Position |
| *b | Retarded Position |
Illustration Description: Shows the camshaft timing gear with a knock pin hole (*1), an alignment mark (*2), and indicators for the Advanced Position (*a) and Retarded Position (*b).
NOTICE:
- If the camshaft timing gear is set to the advanced position, do not let the camshaft timing gear rotate clockwise during installation.
- If the camshaft timing gear has rotated to the most retarded position, make sure to release the lock pin and set the camshaft timing gear to the most advanced position before tightening the camshaft timing gear.
(b) Install the camshaft timing gear as shown in the illustration.
Text in Illustration:
| Label | Description |
|---|---|
| *a | Narrow |
| *b | Wide |
Illustration Description: Shows the camshaft timing gear being installed, with reference to narrow (*a) and wide (*b) sections of the gear.
(c) Turn the camshaft timing gear approximately 180° counterclockwise.
Text in Illustration:
| Label | Description |
|---|---|
| *a | Narrow |
| *b | Wide |
Illustration Description: Depicts the camshaft timing gear being turned approximately 180° counterclockwise, highlighting narrow (*a) and wide (*b) sections.
(d) Align the paint mark with the matchmark to install the chain.
Text in Illustration:
- *1: Paint Mark
- *2: Matchmark
Illustration Description: Shows the timing chain with a paint mark (*1) and a matchmark (*2) being aligned for installation.
(e) Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear.
Text in Illustration:
- *1: Knock Pin Hole
- *2: Knock Pin
Illustration Description: Shows the No. 1 camshaft with its knock pin (*2) aligning with the pin hole (*1) on the camshaft timing gear.
(f) Check that there is no clearance between the camshaft timing gear and camshaft flange.
Text in Illustration:
| Label | Description |
|---|---|
| *1 | Camshaft Timing Gear |
| *2 | Clearance |
| *3 | Camshaft Flange |
| *a | INCORRECT |
| *b | CORRECT |
| *c | No Clearance |
Illustration Description: Similar to step 4(b), this shows the camshaft timing gear (*1) and camshaft flange (*3) with clearance (*2) indicated as INCORRECT (*a), and no clearance (*c) as CORRECT (*b).
(g) Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear by hand.
(h) If the lock pin has not been released, release it.
NOTICE: Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.
- After cleaning and degreasing the intake side VVT oil hole on the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.
Text in Illustration:
- *1: Adhesive Tape Sealing Area
- *a: Make a Hole
Illustration Description: Shows the No. 1 camshaft bearing cap with an oil hole sealed by adhesive tape (*1). A point where a hole is to be made is indicated (*a).
NOTICE: Be sure to seal the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.
- Make a hole in the adhesive tape covering the oil hole as shown in the illustration. (Procedure A)
Illustration Description: Shows air pressure being applied to the hole made in the adhesive tape to release the lock pin.
- Apply approximately 200 kPa (2.0 kgf/cm², 29 psi) of air pressure to the hole made in procedure A to release the lock pin.
NOTICE:
- If air leaks out, reattach the adhesive tape.
- Cover the oil hole with a piece of cloth when applying air pressure to prevent oil from spraying.
- Forcibly turn the camshaft timing gear in the advance direction (counterclockwise).
HINT: Depending on the air pressure applied, the camshaft timing gear may turn in the advance direction without assistance by hand.
- Remove the adhesive tape from the No. 1 camshaft bearing cap.
(i
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