OEM 2009 Toyota FJ Cruiser Camshaft

2009 Toyota FJ Cruiser Camshaft Parts Q&A

• Q: How to install the No. 3 camshaft sub-assembly on 2009 Toyota FJ Cruiser?

  A: The installation of the No. 3 camshaft sub-assembly needs the camshaft to be perfectly horizontal to protect the cylinder head journal surface from any damage. Apply new engine oil to the thrust portion and journal of the camshafts before placing the No. 1 chain on the No. 2 chain of the camshaft timing gear while aligning the yellow mark link with the timing mark (2 dot marks). Mount the camshaft timing gear by fitting its knock pin hole onto the No. 3 camshaft knock pin before pulling in the camshaft timing gear set bolt temporarily. Position the No. 3 camshaft onto bank 2 cylinder head so its No. 2 cylinder facing downward while you maintain the 4 bearing caps in their appropriate positions. Apply thin engine oil layer to all bearing cap bolts threads and torsion areas before you steadily tighten each bolt in a specific order. Constructive steps lead to proper installation of the 8 bearing cap bolts in their correct sequence for the 10 mm (0.39 in.) head (9.0 Nm (92 kgf-cm, 80 in-lbf) torque) and 12 mm (0.47 in.) head (24 Nm (245 kgf-cm, 18 ft-lbf) torque). After aligning the No. 1 chain paint mark with the camshaft timing gears timing marks you should use a wrench to grasp the hexagonal shape of the No. 3 camshaft. Then tighten the camshaft timing gear set bolt to 100 Nm (1,020 kgf-cm, 74 ft-lbf). The procedure for the No. 3 chain tensioner assembly requires you to force the tensioner into its position before placing a pin of dia 1.0 mm (0.039 in.) into the hole to secure it. Next, install the camshaft timing gear and No. 3 chain tensioner by aligning yellow mark links with timing marks of the camshaft timing gears and tighten the No. 3 chain tensioner bolt to 19 Nm (194 kgf-cm, 14 ft-lbf). Follow the same procedure for the No. 4 camshaft sub-assembly by maintaining camshaft level position and aligning knock pin hole with camshaft and temporarily installing camshaft timing gear set bolt before installing bearing caps while applying engine oil to thread sections. Next, tighten all 8 bearing cap bolts according to the specified sequence. While holding the hexagonal shape of No. 4 camshaft with a wrench tighten the camshaft timing gear set bolt to 100 Nm (1,020 kgf-cm, 74 ft-lbf). Finally remove the pin from No. 3 chain tensioner before releasing chain tension. During No. 1 camshaft installation place the yellow mark link on the 1 dot mark of the camshaft timing gear while applying new engine oil and temporarily assembling the No. 1 chain on the No. 2 chain before inserting the knock pin hole into the camshaft timing gear. After installing the camshaft timing gear set bolt workers must position the No. 1 camshaft onto the bank 1 cylinder head with its cam lobes oriented downward before mounting the four bearing caps. The job requires engine oil application on bearing cap bolts threads and bolt heads before tight sequence bolt torquing. Follow these instructions to align the camshaft timing gear timing mark with the bearing cap while lining up the paint mark of the No. 1 chain with the timing mark and gripping the hexagonal portion of the No. 1 camshaft with a wrench before tightening the camshaft timing gear set bolt to 100 Nm (1,020 kgf-cm, 74 ft-lbf). The procedure for the No. 2 chain tensioner assembly includes pushing in the tensioner then inserting a 1.0 mm (0.039 in.) pin to maintain its position. This prepares you for installing the camshaft timing gear and No. 2 chain tensioner before tightening the No. 2 chain tensioner bolt to 19 Nm (194 kgf-cm, 14 ft-lbf). The bank 1 cylinder head installation of the No. 2 camshaft requires it to face upward before the application of engine oil onto bearing cap bolts threads and bolt heads. Next, torque 8 bearing cap bolts to the specified sequence. The mechanic should rotate the No. 2 camshaft clockwise until the knock pin lines up with the timing gear. The mechanic should then hold the hexagonal portion of the camshaft using a wrench and tighten the camshaft timing gear set bolt to 100 Nm (1,020 kgf-cm, 74 ft-lbf). Finally, the mechanic should remove the pin from the No. 2 chain tensioner. First insert a dia 3.5 mm (0.138 in.) bar into the stopper plate while turning the plate clockwise then pushing in the plunger before installing the No. 1 chain tensioner along with its 2 bolts to a torque of 10 Nm (102 kgf-cm, 7.4 ft-lbf). Remove the bar afterward. Secure the timing chain cover plate along with its 4 bolts which require a torque of 9.0 Nm (92 kgf-cm, 80 in-lbf). Rotate the crankshaft pulley through two complete revolutions to align the groove with the "0" timing mark. Inspect the alignment of camshaft timing gear marks with the bearing cap. Set the No. 1 cylinder at TDC/Compression position to inspect and adjust valve clearance. Then install the LH cylinder head cover assembly after applying new seal packing with a bead of 2 to 3 mm (0.08 to 0.12 in.). Keep the installation within 3 minutes after packing application. Tighten the cylinder head cover bolts and nuts uniformly with the following specifications: Bolt A at 10 Nm (102 kgf-cm, 7.4 ft-lbf), Bolt B at 9.0 Nm (92 kgf-cm, 80 in-lbf) and Nut at 9.0 Nm (92 kgf-cm, 80 in-lbf). The V-bank cover installation should follow the completion of ignition coil assembly alongside intake air surge tank No. 2 and No. 1 surge tank stay installation and oil baffle plate while also installing a throttle body bracket and air cleaner assembly before cable connection to the negative battery terminal with 3.9 Nm (40 kgf-cm, 35 in-lbf) torque as well as engine coolant addition and leakage checks alongside ignition timing inspection.