How to install the camshaft timing gear assembly, set the camshafts and timing chain, tighten bolts to specified torques, apply seal packing and O-rings, and complete the final assembly with inspection and coolant addition on 2009 Toyota Tacoma?

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The installation process requires the alignment of key groove and straight pin followed by gentle gear compression on the camshaft until the gear receives the proper alignment with camshaft timing. The procedure ends by turning the gear while pushing at the pin fitting position but avoiding the retard angle side of the camshaft timing gear. First examine the camshaft to gear fringe clearance because then tighten the fringe bolt to a torque of 78 Nm (795 kgf-cm, 58 ft-lbf) while locking the camshaft timing gear in its extreme retard position by enabling it to reach the retard angle side. The engine oil application should be directed towards the camshaft's cam space and cylinder head journal sections before setting the camshaft timing gear with its painted indication at the timing position then positioning both camshafts correctly. Check each No. 2 camshaft bearing cap's proper location before installing them. Then install the No. 1 camshaft bearing cap provisionally. Secure a new O-ring onto the No. 1 camshaft bearing cap before tightening the specified bolts. The order is A first with 12 Nm (122 kgf-cm, 9 ft-lbf) then remaining bolts with 16 Nm (158 kgf-cm, 11 ft-lbf). Check for correct positioning of all timing marks before applying the camshaft timing gear with its timing chain. Adjust the position of the No. 2 camshaft if alignment requires it to achieve this step while ensuring its straight pin aligns with the straight pin hole of the camshaft timing gear. Loosen the hexagonal part of No. 2 camshaft using an adjustable wrench before torquing the bolt to 78 Nm (795 kgf-cm, 58 ft-lbf). Use a 10 mm socket hexagon wrench to fasten a timing gear case head straight screw plug with adhesive applied to 2 or 3 threads while torquing it to 17 Nm (170 kgf-cm, 12 ft-lbf). Attach a new O-ring to the camshaft bearing cap before fitting the timing chain guide by tightening its bolts to 10 Nm (102 kgf-cm, 7 ft-lbf). Seal packing must be applied precisely to the designated areas of the cylinder head cover followed by a surface oil cleanup before the cover gets installed within three minutes of application while engine oil use must be restricted for at least two hours after installation. Use 19 bolts and 2 nuts to provisionally attach the cylinder head cover and tighten bolts A to 9.0 Nm (92 kgf-cm, 80 in-lbf) before tightening bolts B and nuts to the same torque and finally tightening bolts A a second time. Install the ventilation hose and apply 9.0 Nm (92 kgf-cm, 80 in-lbf) torque to ignition coils while installing engine wire harness clamps and connecting the camshaft position sensor connector and VSV connector with throttle and motor body connector and ignition coil connectors. The cable needs to be installed on the negative battery terminal with 3.9 Nm (40 kgf-cm, 35 in-lbf) torque. Then, add engine coolant and inspect for any leakage before putting on the No. 1 engine under cover using 4 bolts at 30 Nm (306 kgf-cm, 22 ft-lbf) torque for Pre Runner and 4WD Type.

OEM 2009 Toyota Tacoma Camshaft

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