Cam Gear Installation Instructions - APR Power

Cam Gear Installation Instructions
2005-2008 Toyota 4.0L
Tacoma
Kit Contents:
2-Exhaust Timing Gears
Tools Required for ECU Installation:
24mm open-end wrench, 22mm box-end
wrench, 22mm socket, 12mm socket,
10mm socket, extension, ratchet Phillips
and Regular Screwdrivers.
1
Cam Gear Installation Instructions
2005-2008 Toyota 4.0L
Tacoma
Removing the air cleaner assembly.
Remove the center-v cover, mass air flow
connector, air cleaner fresh air tube,
throttle body clamp, breather hose and
the air cleaner assembly mounting bolts.
Removing the Intake Manifold.
Remove the manifold VSV connector,
TPS connector and the three wiring
harness clips attached to the manifold.
Remove the brake vacuum hose, EVAP
hose, EVAP connector, oil sensing
connector and the three intake mounting
bracket bolts.
2
Cam Gear Installation Instructions
2005-2008 Toyota 4.0L
Tacoma
Remove the six fasteners that attach the
upper manifold to the lower manifold.
Disconnect the PCV valve hose from
under manifold and remove manifold.
Removing cam covers.
Disconnect all coil connectors, remove
coil retaining bolts, coils and spark plugs.
3
Cam Gear Installation Instructions
2005-2008 Toyota 4.0L
Tacoma
Remove the two EVAP hose brackets.
Remove the wiring harness bracket and
the two manifold stay brackets.
Remove cam cover fasteners and
remove cam covers.
4
Cam Gear Installation Instructions
2005-2008 Toyota 4.0L
Tacoma
Setting Timing Marks
While observing the timing chains, with a
22mm socket rotate the crankshaft
(clockwise) until the following color
pattern develops. This could take several
rotations of the crankshaft, this is the
pattern used to set cam timing when the
engine is being assembled. Two orange
chain straps on the VVT actuators and
four yellow straps on the cam chains. If
the yellow and orange paint no longer
exist, refer to the last page of these
instructions for setting cam timing.
On the drivers side there are two
reference notches on the front side of the
intake and exhaust bearing caps. Rotate
the crankshaft so that the notches on the
bearing cap line up with the cam gear
tooth that is straddled by the two
separate yellow chain straps. There are
two marks on the VVT actuator under the
orange strap of the main timing chain.
When you draw a line from the notch on
the cam bearing through the tooth
straddled by the yellow strap, the line
should pass between these two marks
(timing window for VVTi).
The passenger side is the same (mirror
image) except that there is only one mark
on the VVT actuator, it represents the
tooth location for the orange strap.
5
Cam Gear Installation Instructions
2005-2008 Toyota 4.0L
Tacoma
Once this pattern has been established,
there is a dot on the exhaust gear that
identifies which tooth belongs under the
yellow strap. See illustration below.
Place a paper towel in the under the
exhaust gear to prevent parts from falling
into the front timing cover.
Removing Drivers side exhaust gear:
Install a 24mm wrench on the hex of the
exhaust cam between the #3 exhaust
valves. Install a 22mm wrench on the
cam gear retaining bolt. The threads are
forward threads. The cam gear bolt has a
large face area, you may have to use a
cheater bar or wrench to break it loose.
6
Cam Gear Installation Instructions
2005-2008 Toyota 4.0L
Tacoma
With a 12mm socket, remove the chain
tensioner bolt and the cam gear bolt by
hand.
Using the 24mm wrench, “wiggle” the
cam back and forth while pulling forward
on the gear. This will allow the cam gear
to walk off the shaft.
Once the cam gear is off, note that the
valve spring can cause the exhaust cam
will rotate a few degrees. This will be
corrected during installation.
7
Cam Gear Installation Instructions
2005-2008 Toyota 4.0L
Tacoma
To remove the gear, the tensioner must
pulled up off of it’s locating dowel and the
top slightly tilted towards the rear of the
car. What this does is allow room for the
gear to move towards the Intake cam
gear to disengage the teeth of the gear
from the chain.
Guide the chain over the teeth and remove
gear.
8
Cam Gear Installation Instructions
2005-2008 Toyota 4.0L
Tacoma
Installing new driver side gear
Locate the dot on the gear and the yellow
strap of the chain. (Note that the new
gear has “Front” etched into the gear,
make sure that this and the dot faces the
front of the vehicle)
Install the gear so that the tooth above the
dot is straddled by the yellow strap.
Tilt the tensioner so that the gear can be
inserted into the chain (check the dot and
strap).
9
Cam Gear Installation Instructions
2005-2008 Toyota 4.0L
Tacoma
Once the gear is in place, move the chain
tensioner back on to its dowel pin.
Using your left hand, push down on the
tensioner with your thumb and push the
gear towards the rear of the car with your
index finger. With your right hand, rotate
the camshaft so that the dowel on the
camshaft lines up with the dowel hole on
the gear. Once you have it aligned,
“wiggle” the camshaft to walk the gear
back on to the cam.
Install chain tensioner bolt and cam gear
bolt. Torque the tensioner bolt to 14 Ft.lbs
/ 19Nm and the camshaft gear bolt to 74
ft. lbs. / 100Nm.
10
Cam Gear Installation Instructions
2005-2008 Toyota 4.0L
Tacoma
Remove Paper Towel
Removing passenger side gear
Just like the driver side, there is a dot on
the exhaust gear that identifies which
tooth belongs under the yellow strap. See
illustration below.
Loosen the cam gear and tensioner bolt
and insert paper towel.
11
Cam Gear Installation Instructions
2005-2008 Toyota 4.0L
Tacoma
Verify timing marks and remove cam gear
bolt and tensioner bolt.
Using the 24mm wrench, “wiggle” the
cam back and forth while pulling forward
on the gear. This will allow the cam gear
to walk off the shaft.
To remove the gear, the tensioner must
pulled up off of it’s locating dowel and the
top slightly tilted towards the rear of the
car. Move the gear towards the intake cam
gear to disengage the teeth of the gear
from the chain.
12
Cam Gear Installation Instructions
2005-2008 Toyota 4.0L
Tacoma
Remove gear.
Installing new passenger side gear
Locate the dot on the gear and the yellow
strap of the chain.
Install the gear so that the tooth above the
“dot” is straddled by the yellow strap.
13
Cam Gear Installation Instructions
2005-2008 Toyota 4.0L
Tacoma
Tilt the tensioner so that the gear can be
inserted into the chain (check the dot and
strap).
Once the gear is in place, move the chain
tensioner back on to its dowel pin and
verify timing marks.
Using your right hand, push the gear
towards the rear of the car. With your left
hand, rotate the camshaft so that the
dowel on the camshaft lines up with the
dowel hole on the gear. Once you have it
aligned, “wiggle” the camshaft to walk the
gear back on.
14
Cam Gear Installation Instructions
2005-2008 Toyota 4.0L
Tacoma
Verify timing marks and remove cam gear
bolt and tensioner bolt. (Note that the new
gear has “Front” etched into the gear,
make sure that this and the dot faces the
front of the vehicle)
Install chain tensioner bolt and cam gear
bolt. Torque the tensioner bolt to 14 ft.lbs.
/ 19Nm and the camshaft gear bolt to 74
ft. lbs./ 100Nm.
Remove paper towel.
Install Cam covers, inlet manifold and air
cleaner assembly.
15
Cam Gear Installation Instructions
2005-2008 Toyota 4.0L
Tacoma
16