Timing Belt: Installation

1. Align the timing pulley set key with the key groove of the pulley.
2. Using SST and a hammer, tap in the timing pulley, facing the flange side inward.

   SST 09223-4601 1

Fig 1: Tapping In Timing Pulley Using SST And Hammer

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1. Apply adhesive 2 or 3 threads of the pivot bolt.

   Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

   Fig 2: Applying Adhesive 2 Or 3 Threads Of Pivot Bolt

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2. Using a 10 mm hexagon wrench, install the plate washer and idler pulley with the pivot bolt.

   Torque: 34.5 N.m (350 kgf.cm, 25 ft.lbf) 

3. Check that the pulley bracket moves smoothly.

1. Install the idler pulley with the bolt.

   Torque: 34.5 N.m (350 kgf.cm, 25 ft.lbf) 

2. Check that the idler pulley moves smoothly.

1. Remove any oil or water on the crankshaft pulley, oil pump pulley, water pump pulley, No.1 idler pulley and No.2 idler pulley, and keep them clean.
   NOTE: Only wipe the pulleys; do not use any cleansing agent.
2. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
   Fig 3: Aligning Installation Mark On Timing Belt

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3. Install the timing belt on the crankshaft timing pulley, No.1 idler pulley and No.2 idler pulley.

1. Install the gasket to the cover spacer.
2. Install the cover spacer.
   Fig 4: Installing Cover Spacer

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Install the belt guide, facing the cup side outward.

Install the timing belt cover with the 4 bolts.

1. Align the pulley set key with the key groove of the crankshaft pulley.
2. Using SST and a hammer, tap in the crankshaft pulley.

   SST 09223-4601 1

Fig 5: Tapping Crankshaft Pulley Using SST And Hammer

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Install the belt tensioner with the bolt and 2 nuts.

Torque: 15.5 N.m (160 kgf.cm, 11 ft.lbf) 

HINT:

Use a bolt 106 mm (4.18 in.) in length.

Fig 6: Installing Drive Belt Tensioner Bolt And Nuts

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Check that the timing mark of the crankshaft pulley is aligned with the centers of the crankshaft pulley and the No.2 timing belt idler pulley bolt.

Fig 7: Checking Timing Mark Of Crankshaft Pulley Is Aligned

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1. Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
2. Attach the timing pulley to the camshaft timing tube, facing the "L" mark forward.
3. Using SST, install the 4 pulley bolts.

   SST 09960-10010 (09962-01000, 09963-00350)

   Torque: 7.5 N.m (80 kgf.cm, 66 in..lbf) 

Fig 8: Installing Camshaft Timing Pulley Bolts (LH)

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1. Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
2. Attach the timing pulley to the camshaft timing tube, facing the "R" mark forward.
3. Using SST, install the 4 pulley bolts.

   SST 09960-10010 (09962-01000, 09963-00350)

   Torque: 7.5 N.m (80 kgf.cm, 66 in. lbf) 

Fig 9: Installing Camshaft Timing Pulley Bolts (RH)

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1. Remove any oil or water on the timing pulley, and keep it clean.
   NOTE: Only wipe the pulleys; do not use any cleansing agent.
2. Using SST, turn the timing pulley. Align the installation mark on the timing belt with the timing mark of the timing pulley, and hang the timing belt on the timing pulley.

   SST 09960-10010 (09962-01000, 09963-00350)

   Fig 10: Aligning Installation Mark On Timing Belt With Timing Mark Of Timing Pulley (LH)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, turn the LH camshaft timing pulley counterclockwise until there is tension between the crankshaft timing pulley and LH camshaft timing pulley.

   SST 09960-10010 (09962-01000, 09963-00350)

Fig 11: Turning LH Camshaft Timing Pulley Counterclockwise Using SST (LH)

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1. Remove any oil or water on the camshaft timing pulley and water pump pulley, and keep them clean.
   NOTE: Only wipe the pulleys; do not use any cleansing agent.
2. Using SST, turn the timing pulley. Align the installation mark on the timing belt with the timing mark of the timing pulley, and hang the timing belt on the timing pulley.

   SST 09960-10010 (09962-01000, 09963-00350)

Fig 12: Aligning Installation Mark On Timing Belt With Timing Mark Of Timing Pulley (RH)

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1. Using a press, slowly press in the push rod using 981-9,807 N (100 - 1,000 kgf, 220 - 2,205 lbf) of pressure.
2. Align the holes of the push rod and housing, pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.
   Fig 13: Aligning Holes Of Push Rod And Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Release the press.
4. Install the dust boot to the belt tensioner.

1. Temporarily install the belt tensioner with the 2 bolts.
2. Alternately tighten the 2 bolts.

   Torque: 26 N.m (270 kgf.cm, 19 ft.lbf) 

3. Using pliers, remove the 1.27 mm hexagon wrench from the belt tensioner.

Fig 14: Removing Hexagon Wrench From Belt Tensioner

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1. Temporarily install the crankshaft pulley bolt.
2. Slowly turn the crankshaft pulley 2 revolutions from TDC to TDC.
   NOTE: Always turn the crankshaft pulley clockwise.
   Fig 15: Turning Crankshaft Pulley 2 Revolutions From TDC To TDC

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3. Check that each pulley aligns with the timing marks as shown in Fig 16 .

If the timing marks do not align, remove the timing belt and reinstall it.

Fig 16: Checking Each Pulley Aligns With Timing Marks

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Using SST, install the pulley bolt.

SST 09213-7001 1, 09330-00021

Torque: 245 N.m (2,500 kgf.cm, 181 ft.lbf) 

Fig 17: Tightening Crankshaft Pulley Bolt

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Install the idler pulley with the 2 bolts and 2 nuts.

Torque: 

16 N.m (160 kgf.cm, 12 ft.lbf) for 

12 mm head 32 N.m (330 kgf.cm, 24 ft.lbf) for 14 mm head 

HINT:

• Each bolt length is indicated in Fig 18 .

  Bolt Length:

  106 mm (4.17 in.) for 12 mm head (A)

  114 mm (4.49 in.) for 14 mm head (B)

  Fig 18: Installing No.1 Drive Belt Idler Pulley Bolts And Nuts

  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
• Pass the engine wire for the crankshaft position sensor between the idler pulley and oil pump.

1. Fit the timing belt cover, matching the claws and pin with each part.
2. Install the timing belt cover with the 2 bolts.

   Torque: 16 N.m (160 kgf.cm, 12 ft.lbf) 

HINT:

Use bolts 106 mm (4.17 in.) in length.

Fig 19: Installing No.2 Timing Belt Cover Bolts

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1. Install the gasket to the timing belt cover.
2. Install the timing belt cover with the cap nut and 3 bolts.
3. Install the 2 PS air hoses to the clamp on the timing belt cover.

Fig 20: Installing PS Air Hoses To Clamp On Timing Belt Cover

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1. Install the gasket to the LH No.3 timing belt cover.
2. Run the camshaft position sensor wire through the timing belt cover hole.
3. Install the LH No.3 timing belt cover with the 4 bolts.
4. Install the wire grommet to the LH No.3 timing belt cover.
   Fig 21: Installing Wire Grommet To LH No. 3 Timing Belt Cover

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5. Install the sensor connector to the connector holder.
6. Connect the sensor connector.
7. Install the sensor wire to the wire clamp on the LH No.3 timing belt cover.
8. Install the connector holder to the LH No.3 timing belt cover.
9. Install the engine wire to the 2 wire clamps on the LH No.3 timing belt cover.
10. Connect the 2 water bypass hoses to the No.3 water bypass pipe.
    Fig 22: Connecting Water Bypass Hoses To Water Bypass Pipe

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11. Install the No.3 water bypass pipe to the LH No.3 timing belt cover with the cap nut.

Install the idler pulley and cover plate with the bolt.

Torque: 39 N.m (398 kgf.cm, 29 ft.lbf)