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: Taping In Timing Pulley Using SST

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

   Adhesive: 

   Part No. 08833-00080, THREE BOND 1344, 

   LOCTITE® 242 or equivalent 

2. Using a 10 mm hexagon wrench, install the plate washer and the No. 1 idler pulley with the pivot bolt.

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

3. Install the No. 2 idler pulley with the bolt.

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

4. Check that the No. 1 and No. 2 idler pulley moves smoothly.

Fig 2: Installing No. 1 Idler Pulley And No. 2 Idler Pulley Using SST

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1. Remove any oil or water on and clean the crankshaft pulley, the oil pump pulley, the water pump pulley, the No. 1 idler pulley and the No. 2 idler pulley.
   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.
3. Install the timing belt on the crankshaft timing pulley, the No. 1 idler pulley and the No. 2 idler pulley.

1. Install the gasket to the cover spacer.
2. Install the cover spacer.

Fig 3: Aligning Mark On Timing Belt

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Install the belt guide, facing the cup side outward.

Fig 4: Installing Timing Belt Guide

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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: Taping In Crankshaft Pulley Using SST

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Install the belt tensioner with the bolt and the 2 nuts.

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

HINT:

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

Check that the timing mark of the crankshaft pulley is aligned with timing mark "0" of the No. 1 timing belt cover.

Fig 6: Aligning Timing Mark

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1. Align the camshaft knock pin with the knock pin grove of the timing pulley, and slide on the timing pulley.
2. Using SST, install the pulley bolt.

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

   Torque: 108 N.m (1,100 kgf.cm, 80 ft.lbf) 

Fig 7: Installing Pulley Bolt Using SST

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1. Remove any oil or water on the LH camshaft timing pulley, and clean it up.
   NOTE: Only wipe the pulleys; do not use any cleansing agent.
2. Turn the LH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley, and hang the timing belt on the LH camshaft timing pulley.
   Fig 8: Turning LH Camshaft Timing Pulley And Aligning Mark

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

Fig 9: Tensioning Belt With LH Camshaft

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

Fig 10: Turning RH Camshaft Timing Pulley And Aligning Mark

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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 the housing, pass a 1.27 mm (0.050 in.) hexagon wrench through the holes to keep the setting position of the push rod.
3. Release the press.
4. Install the dust boot to the belt tensioner.

Fig 11: Aligning Holes Of Push Rod And Housing

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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 (0.050 in.) hexagon wrench from the belt tensioner.

Fig 12: Installing Timing 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 13: Installing Crankshaft Pulley Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check that each pulley aligns with the timing marks as shown in the illustration.

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

Fig 14: Checking Timing Marks

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Using SST, install the pulley bolt.

SST 09213-7001 1 (90105-70020), 09330-00021

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

Fig 15: Installing Pulley Bolt Using SST

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Install the fan bracket with the 2 bolts and the 2 nuts.

Torque: 

1. 12 mm head 
   1. 16 N.m (160 kgf.cm, 12 ft.lbf) 
2. 14 mm head 
   1. 32 N.m (330 kgf.cm, 24 ft.lbf) 

HINT:

Bolt Length:

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

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

Fig 16: Identifying Fan Bracket

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Install the No. 2 timing belt cover with the 2 bolts.

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

Fig 17: Installing No. 2 Timing Belt Cover With Bolts

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1. Fit the RH No. 3 timing belt cover, matching it with the fan bracket.
2. Install the RH No. 3 timing belt cover with the 3 bolts and nut.

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

Fig 18: Installing RH No. 3 Timing Belt Cover

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1. Install the oil cooler pipe and the bolt.
2. Run the camshaft position sensor wire through the LH No. 3 timing belt cover hole.
3. Fit the LH No. 3 timing belt cover, matching it with the fan bracket.
4. Install the LH No. 3 timing belt cover with the 4 bolts and the nut.

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

5. Install the wire grommet to the LH No. 3 timing belt cover.
6. Install the sensor connector to the connector bracket.
7. Connect the sensor connector.
8. Install the sensor wire to the wire clamp on 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.

Fig 19: Installing LH No. 3 Timing Belt Cover

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Install the idler pulley and the cover plate with the bolt.

Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 

(See  INSTALLATION  ) 

1. Temporarily install the fan pulley, the fan, the fluid coupling assembly with the 4 nuts.
Fig 20: Installing Fan Pulley, Fan, Fluid Coupling And Drive Belt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the generator drive belt.

   (See INSTALLATION )

3. Tighten the 4 nuts holding the fluid coupling to the fan bracket.

   Torque: 21 N.m (215 kgf.cm, 16 ft.lbf)