Timing Chain: Installation

INSTALL NO. 2 CHAIN SUB-ASSEMBLY
1. Set the crankshaft key in the left horizontal position.
  
  Fig 1: Setting Crankshaft Key In Left Horizontal Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Turn the cutout of the drive shaft to the top.
3. Align the yellow mark links with the timing marks of the each gear as shown in the illustration.
4. Install the gears onto the crankshaft and oil pump shaft with the chain wrapped on the gears.
5. Temporarily tighten the oil pump drive shaft gear with the nut.
6. Insert the damper spring into the adjusting hole, then install the chain tensioner plate with the bolt.
  Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
  
  Fig 3: Identifying Chain Tensioner Plate With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pump.
8. Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, then tighten the nut.
  Torque: 29.5 N*m (301 kgf*cm, 22 ft.*lbf)
  
  Fig 4: Inserting Diameter Bar Into Adjusting Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Turn the crankshaft clockwise by 90° to position the crankshaft key upward.
  
  Fig 5: Turning Crankshaft Clockwise To Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT TIMING SPROCKET
INSTALL NO. 1 CHAIN VIBRATION DAMPER
1. Install the chain vibration damper with the 2 bolts.
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
INSTALL CHAIN SUB-ASSEMBLY
1. Set the No. 1 cylinder to TDC/compression.
  1. Turn the camshafts with a wrench in the hexagonal lobe to align the timing marks of the camshaft timing gear with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration.
    
    Fig 6: Aligning Timing Marks With Each Timing Mark
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Using the crankshaft pulley bolt, turn the crankshaft to position the key on the crankshaft upward.
    
    Fig 7: Turning Crankshaft To Position Key On Crankshaft Upward
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the chain onto the crankshaft timing sprocket with the gold or orange mark link aligned with the timing mark on the crankshaft timing gear.
  
  Fig 8: Identifying Timing Mark On Crankshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a hammer, tap in the crankshaft timing sprocket.
  SST 09309-37010
  
  Fig 9: Tapping In Crankshaft Timing Sprocket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Align the gold or yellow links with each timing mark located on the camshaft timing gear and sprocket, then install the chain.
  
  Fig 10: Identifying Mark Link And Timing Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CHAIN TENSIONER SLIPPER
1. Install the chain tensioner slipper with the bolt.
  Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
INSTALL TIMING CHAIN GUIDE
1. Install the timing chain guide with the bolt.
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
  
  Fig 11: Identifying Timing Chain Guide With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE
1. Install the sensor plate with the "F" mark facing forward.
  
  Fig 12: Identifying Sensor Plate With "F" Mark Facing Forward
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

Remove any old packing material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.
Apply of seal packing (Diameter 2.0 mm (0.079 in.)) as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTE:
- Remove any oil from the contact surface.
- Install the chain cover within 3 minutes of applying seal packing.
- Do not add engine oil for at least 2 hours after installing the chain cover.
  
  Fig 13: Identifying Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Apply a continuous bead of seal packing as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTE:
- Remove any oil from the contact surface.
- Install the chain cover within 3 minutes of applying seal packing.
- Do not add engine oil for at least 2 hours after installing the chain cover.
  
  Fig 14: Applying Continuous Bead Of Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the timing chain cover with the 14 bolts and 2 nuts.

Torque:

9.0 N*m (92 kgf*cm, 80 in.*lbf) for bolt A

25 N*m (255 kgf*cm, 18 ft.*lbf) for bolt B

55 N*m (561 kgf*cm, 41 ft.*lbf) for bolt C

11 N*m (112 kgf*cm, 8 ft.*lbf) for nut

HINT:

Bolt length:

BOLT LENGTH

Bolt A	30 mm (1.18 in.) length for 10 mm head
Bolt B	30 mm (1.18 in.) length for 12 mm head
Bolt C	40 mm (1.57 in.) length for 14 mm head
Bolt D	65 mm (2.56 in.) length for 14 mm head

Fig 15: Identifying Timing Chain Cover Bolts And Nuts

Using an E10 "torx" socket, install the stud bolt for the V-ribbed belt tensioner.
Torque: 21.5 N*m (219 kgf*cm, 16 ft.*lbf)

Fig 16: Identifying Stud Bolt For V-Ribbed Belt Tensioner
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
1. Release the ratchet pawl, then fully push in the plunger and hook the hook to the pin so that the plunger is in the position shown in the illustration.
  
  Fig 17: Pushing In Plunger And Hook To Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install a new gasket and the chain tensioner with the 2 nuts.
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
  
  NOTE: When installing the chain tensioner, set the hook again if the hook releases the plunger.
  
  Fig 18: Identifying Gasket And Chain Tensioner With Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT PULLEY
1. Using SST, fix the pulley in place and tighten the bolt.
  SST 09213-54015 (91651-60855), 09330-00021
  
  Torque: 180 N*m (1,835 kgf*cm, 133 ft.*lbf)
  
  Fig 19: Identifying Pulley Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Turn the crankshaft counterclockwise, then disconnect the plunger knock pin from the hook.
  
  Fig 20: Identifying Plunger Knock Pin From Hook
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Turn the crankshaft clockwise, then check that the plunger is extended.
  
  Fig 21: Turning Crankshaft Clockwise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Connect the wire harness protector clamp.
  
  Fig 22: Identifying Wire Harness Protector Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the bolt.
  Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf)
INSTALL OIL PAN SUB-ASSEMBLY
1. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.
2. Apply a continuous bead of seal packing (Diameter 3.0 to 4.0 mm (0.118 to 0.157 in.)) as shown in the illustration.
  Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Install the oil pan within 3 minutes of applying seal packing.
  - Do not add engine oil for at least 2 hours after installing the oil pan.
  Fig 23: Applying Continuous Bead Of Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the oil pan to the cylinder block.
4. Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration.
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
  
  Fig 24: Identifying Oil Pan Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Place a transmission jack underneath the engine, then put a wooden block on the jack.
6. Remove the chain block and sling device.
7. Remove the No. 1 and No. 2 engine hangers.
INSTALL CRANKSHAFT POSITION SENSOR (See INSTALLATION )
INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
1. Install the V-ribbed belt tensioner with the bolt and nut.
  Torque: 59.5 N*m (607 kgf*cm, 44 ft.*lbf)
  
  NOTE: Do not lift the engine more than necessary.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
1. Remove any old packing material from the contact surface.
  
  Fig 26: Identifying V-Ribbed Belt Tensioner With Bolt And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply seal packing to the 2 locations shown in the illustration.
  Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Install the oil pan within 3 minutes of applying seal packing.
  - Do not add engine oil for at least 2 hours after installing the oil pan.
    
    Fig 27: Applying Seal Packing Locations
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the cylinder head cover with the 8 bolts and 2 nuts.
  Torque:
  
  11 N*m (112 kgf*cm, 8 ft.*lbf) for bolt A
  
  14 N*m (143 kgf*cm, 10 ft.*lbf) for bolt B
  
  11 N*m (112 kgf*cm, 8 ft.*lbf) for nut
  
  Fig 28: Identifying Cylinder Head Cover With 8 Bolts And 2 Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the engine wire with the bolt (labeled A).
  Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)
5. Connect the clamp of the engine wire (labeled B).
  
  Fig 29: Identifying Clamp Of Engine Wire And Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Connect the 2 ventilation hoses to the cylinder head cover.
  
  Fig 30: Identifying Ventilation Hoses To Cylinder Head Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL IGNITION COIL ASSEMBLY (See INSTALLATION )
INSTALL ENGINE MOUNTING INSULATOR RH
1. Install the engine mounting insulator RH with the 4 bolts and 2 nuts.
  Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf)
  
  Fig 31: Identifying Engine Mounting Insulator RH With Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the front engine mounting insulator with the bolt and nut.
  Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf)
  
  Fig 32: Identifying Front Engine Mounting Insulator With Bolt And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the 2 clamps of the engine wire.
4. Install the wire harness protector with the bolt.
5. Install the No. 1 oil reservoir bracket with the 2 bolts.
  Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)
  
  Fig 34: Identifying No. 1 Oil Reservoir Bracket With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the return tube with the 2 bolts.
  Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)
  
  Fig 35: Identifying Return Tube Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install the vane pump oil reservoir onto the No. 1 oil reservoir bracket.
  
  Fig 36: Identifying Vane Pump Oil Reservoir Onto No. 1 Oil Reservoir Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Install the radiator reservoir with the bolt.
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
  
  Fig 37: Identifying Radiator Reservoir With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VANE PUMP ASSEMBLY
INSTALL GENERATOR ASSEMBLY (See INSTALLATION )
INSTALL FAN AND GENERATOR V BELT (See INSTALLATION )
INSTALL FRONT EXHAUST PIPE ASSEMBLY (See INSTALLATION )
ADD ENGINE OIL (See REPLACEMENT )
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
CHECK FOR ENGINE OIL LEAKS
CHECK FOR EXHAUST GAS LEAKS
INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY
1. Install the engine cover with the 2 nuts.
  Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)
  
  Fig 38: Identifying Cover With Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT FENDER APRON SEAL RH
INSTALL ENGINE UNDER COVER LH
INSTALL ENGINE UNDER COVER RH
INSTALL FRONT WHEEL RH
INSTALL HOOD SUB-ASSEMBLY
PERFORM INITIALIZATION
1. Perform initialization (see INITIALIZATION ).
  NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.