Last Modified: 04-05-2023 6.11:8.1.0 Doc ID: RM100000000VICQ
Model Year Start: 2016 Model: Sienna Prod Date Range: [12/2015 - 08/2016]
Title: 2GR-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION; 2016 MY Sienna [12/2015 - 08/2016]

INSTALLATION

PROCEDURE

1. INSTALL NO. 3 CAMSHAFT

(a) Apply a light coat of engine oil to the No. 3 camshaft journals and camshaft housing sub-assembly LH.

(b) Install the No. 3 camshaft to the camshaft housing sub-assembly LH.

2. INSTALL NO. 4 CAMSHAFT

(a) Apply a light coat of engine oil to the No. 4 camshaft journals and camshaft housing sub-assembly LH.

(b) Install the No. 4 camshaft to the camshaft housing sub-assembly LH.

3. INSTALL CAMSHAFT BEARING CAP (for Bank 2)

(a) Apply engine oil to the camshaft bearing caps.

(b) Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.

(c) Temporarily tighten the 8 bolts in the order shown in the illustration.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

4. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH

(a) Make sure that the valve rocker arm is installed as shown in the illustration.

Text in Illustration

*1

Valve Rocker Arm

*2

Lash Adjuster

*3

Valve Stem

*4

Valve Stem Cap

(b) Apply seal packing in a continuous line as shown in the illustration.

Text in Illustration

*a

Seal packing diameter

(3.5 to 4.5 mm)

Seal packing:

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

Seal diameter:

3.5 to 4.5 mm (0.138 to 0.177 in.)

NOTICE:

  • Remove any oil from the contact surface.
  • Install the camshaft housing sub-assembly LH within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
  • Do not start the engine for at least 2 hours after installing.

(c) Install the camshaft housing sub-assembly LH and tighten the 13 bolts in the order shown in the illustration.

Text in Illustration

*1

Knock Pin

*a

Front View

Torque:

28 N·m {286 kgf·cm, 21 ft·lbf}

NOTICE:

  • When installing the camshaft housing sub-assembly LH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.
  • If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly LH, clean the installation surfaces, and reapply seal packing.
  • If the camshaft housing sub-assembly LH is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.

(d) Tighten the 8 bolts in the order shown in the illustration.

Torque:

16 N·m {163 kgf·cm, 12 ft·lbf}

5. INSTALL CAMSHAFT

(a) Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly RH.

(b) Install the camshaft to the camshaft housing sub-assembly RH.

6. INSTALL NO. 2 CAMSHAFT

(a) Apply a light coat of engine oil to the No. 2 camshaft journals and camshaft housing sub-assembly RH.

(b) Install the No. 2 camshaft to the camshaft housing sub-assembly RH.

7. INSTALL CAMSHAFT BEARING CAP (for Bank 1)

(a) Apply engine oil to the camshaft bearing caps.

(b) Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.

(c) Temporarily tighten the 8 bearing cap bolts in the order shown in the illustration.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

8. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

(a) Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.

Text in Illustration

*1

Valve Rocker Arm

*2

Lash Adjuster

*3

Valve Stem

*4

Valve Stem Cap

(b) Apply seal packing in a continuous line as shown in the illustration.

Text in Illustration

*a

Seal packing diameter

(3.5 to 4.5 mm)

Seal packing:

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

Seal diameter:

3.5 to 4.5 mm (0.138 to 0.177 in.)

NOTICE:

  • Remove any oil from the contact surface.
  • Install the camshaft housing sub-assembly RH within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
  • Do not start the engine for at least 2 hours after installing.

(c) Install the camshaft housing sub-assembly RH and tighten the 12 bolts in the order shown in the illustration.

Text in Illustration

*1

Knock Pin

*a

Front View

Torque:

28 N·m {286 kgf·cm, 21 ft·lbf}

NOTICE:

  • When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown in the illustration.

    Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.

  • If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly RH, clean the installation surfaces, and reapply seal packing.
  • If the camshaft housing sub-assembly RH is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.

(d) Tighten the 8 bolts in the order shown in the illustration.

Torque:

16 N·m {163 kgf·cm, 12 ft·lbf}

9. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

(a) Install the No. 3 chain tensioner assembly with the bolt.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(b) While pushing in the tensioner, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold it.

Text in Illustration

*1

Plunger

*2

Pin

*a

Push

10. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)

(a) Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.

Text in Illustration

*1

Timing Mark

*2

Mark Plate (yellow)

(b) Apply a light coat of engine oil to the bolt threads and bolt-seating surface.

(c) Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear LH with the No. 2 chain sub-assembly installed.

(d) Using SST to hold the hexagonal portion of each camshaft, tighten the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly LH.

Text in Illustration

*a

Turn

*b

Hold

SST: 09922-10010

Torque:

100 N·m {1020 kgf·cm, 74 ft·lbf}

(e) Remove the pin from the No. 3 chain tensioner assembly.

11. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Install the No. 2 chain tensioner assembly with the bolt.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(b) While pushing in the No. 2 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold it.

Text in Illustration

*1

Plunger

*2

Pin

*a

Push

12. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)

(a) Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.

Text in Illustration

*1

Timing Mark

*2

Mark Plate (yellow)

(b) Apply a light coat of engine oil to the bolt threads and bolt-seating surface.

(c) Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the No. 2 chain sub-assembly installed.

(d) Using SST to hold the hexagonal portion of each camshaft, tighten the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly RH.

Text in Illustration

*a

Turn

*b

Hold

SST: 09922-10010

Torque:

100 N·m {1020 kgf·cm, 74 ft·lbf}

(e) Remove the pin from the No. 2 chain tensioner assembly.

13. INSTALL IDLE SPROCKET ASSEMBLY

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY+

14. INSTALL CHAIN SUB-ASSEMBLY

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY+

15. INSTALL CHAIN TENSIONER SLIPPER

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY+

16. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY+

17. INSPECT VALVE TIMING

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY+

18. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE LUBRICATION: OIL PUMP: INSTALLATION+

19. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE LUBRICATION: OIL PUMP: INSTALLATION+

20. INSTALL WATER INLET HOUSING

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY+

21. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY+

22. INSTALL OIL PAN SUB-ASSEMBLY

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY+

23. INSTALL OIL STRAINER SUB-ASSEMBLY

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY+

24. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY+

25. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY+

26. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH (for Bank 2)

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY+

27. INSTALL CRANKSHAFT PULLEY

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: FRONT CRANKSHAFT OIL SEAL: INSTALLATION+

28. INSTALL NO. 1 OIL PIPE

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY+

29. INSTALL OIL PIPE

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY+

30. INSTALL CRANKSHAFT POSITION SENSOR

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE (ENGINE CONTROL): CRANKSHAFT POSITION SENSOR: INSTALLATION+

31. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSTALLATION+

32. INSTALL WATER PUMP PULLEY

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE COOLING: WATER PUMP: INSTALLATION+

33. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSTALLATION+

34. INSTALL NO. 2 TIMING GEAR COVER

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSTALLATION+

35. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSTALLATION+

36. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY

(See page 2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE INTAKE / EXHAUST: EXHAUST MANIFOLD: INSTALLATION )

37. INSTALL INTAKE MANIFOLD

(See page 2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE INTAKE / EXHAUST: INTAKE MANIFOLD: INSTALLATION )

38. INSTALL IGNITION COIL ASSEMBLY

(See page 2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE (ENGINE CONTROL): IGNITION COIL AND SPARK PLUG: INSTALLATION )

39. INSTALL ENGINE HANGER

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSTALLATION+

40. REMOVE ENGINE FROM ENGINE STAND

41. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: REAR CRANKSHAFT OIL SEAL: INSTALLATION+

42. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD)

(See page 2016 MY Sienna [12/2015 - 08/2016]; U660E (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY(When Not Using the Engine Support Bridge): INSTALLATION )

43. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for AWD)

(See page 2016 MY Sienna [12/2015 - 08/2016]; U660F (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE ASSEMBLY(When Not Using the Engine Support Bridge): INSTALLATION )