Timing Chain: Installation

1. Set the No. 1 cylinder to the TDC/compression.
   1. Turn the hexagonal wrench head portion of the camshafts until the point marks of the 2 camshaft timing gears are aligned.
      Fig 1: Aligning Points Marks On Camshaft

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using a crankshaft pulley bolt, turn the crankshaft to align the timing gear key with the point mark on the oil pump.
      Fig 2: Aligning Timing Gear Key With Point Mark On Oil Pump

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the chain onto the crankshaft timing gear with the yellow mark link aligned with the timing mark on the crankshaft timing gear.
   Fig 3: Identifying Crankshaft Timing Gear With Yellow Mark Link

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, install the crankshaft timing gear.

   SST 09223-22010 

   Fig 4: Installing Crankshaft Timing Gear With SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the chain onto the camshaft timing gears with the yellow mark links aligned with the timing marks on the camshaft timing gears.
   Fig 5: Installing Chain Onto Camshaft Timing Gears

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the chain tensioner slipper with the bolt.

   Torque: 18.5 N*m (189 kgf*cm, 14 ft.*lbf) 

   Fig 6: Locating Chain Tensioner Slipper With Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the crankshaft position sensor plate with the "F" mark facing forward.

Fig 7: Identifying Crankshaft Position Sensor Plate No.1

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1. Apply a light coat of multi-purpose grease to a new oil seal lip.
2. Place the timing chain cover on wooden blocks.
   Fig 8: Placing Timing Chain Cover On Wooden Blocks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, tap the oil seal in until its surface is flush with the timing chain cover edge.

   SST 09223-22010 

   NOTE: Keep the lip free of foreign objects.

1. Remove any old packing material from the contact surface.
2. Apply a continuous bead of seal packing (Diameter 3.5 to 4.5 mm (0.138 to 0.177 in.)) as shown in the illustration.

   Seal packing: 

   Water pump part: 

   Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent 

   Other part: 

   Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent 

   Fig 9: Applying Continuous Bead Of Seal Packing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Remove any oil from the contact surface.
   • Install the chain cover within 3 minutes of applying seal packing.
   • Do not start the engine for at least 2 hours after installing the chain cover.
   • Be careful to only apply the specified thickness / volume of seal packing in area D.
     Fig 10: Identifying Dimension Of Timing Chain Cover

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the timing chain cover with the 10 bolts and 2 nuts.

   Torque: Bolt A and nut A 

   13 N*m (133 kgf*cm, 10 ft.*lbf) 

   Bolt B 

   18.5 N*m (189 kgf*cm, 14 ft.*lbf) 

   Fig 11: Locating Timing Chain Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a "TORX" socket wrench (E8), install the stud bolt.

   Torque: 9.5 N*m (97 kgf*cm, 84 in.*lbf) 

1. Check that the O-ring is clean, then set the hook as shown in the illustration.
2. Apply a light coat of engine oil to the O-ring.
   Fig 12: Setting Hook

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the chain tensioner with the 2 nuts.

   Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

   NOTE:

   • Be careful not to twist the O-ring.
   • When installing the chain tensioner, set the hook again if the hook releases the plunger.
     Fig 13: Installing Chain Tensioner

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Align the pulley set key with the key groove of the crankshaft pulley, then slide on the crankshaft pulley.
2. Using SST, install the crankshaft pulley bolt.

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

   Torque: 138 N*m (1,407 kgf*cm, 102 ft.*lbf) 

   Fig 14: Installing Crankshaft Pulley Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Turn the crankshaft counterclockwise to disconnect the plunger knock pin from the hook.
   Fig 15: Turning Crankshaft Counterclockwise

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Turn the crankshaft clockwise, then check that the slipper is pushed by the plunger.

   If the plunger is not extended, push the slipper into the chain tensioner using a screwdriver so that the hook is released from the knock pin and the plunger can be extended.

Fig 16: Turning Crankshaft Clockwise
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply a light coat of engine oil to the O-ring of the crankshaft position sensor.
2. Install the crankshaft position sensor with the 2 bolts.

   Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

1. Install the water pump assembly (See REMOVAL ).

Torque: 47 N*m (479 kgf*cm, 35 ft.*lbf) 

1. Install the V-ribbed belt tensioner with the bolt and nut.

   Torque: Bolt 

   69 N*m (704 kgf*cm, 51 ft.*lbf) 

   Nut 

   29 N*m (296 kgf*cm, 21 ft.*lbf) 

   Fig 17: Installing V-Ribbed Belt Tensioner

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove any old packing material from the contact surface.
2. Apply seal packing to the 2 locations 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 cylinder head cover within 3 minutes of applying seal packing.
   • Do not put in engine oil for at least 2 hours after installation.
     Fig 18: Applying Seal Packing To Locations

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the cylinder head cover and 3 clamp brackets with the 9 bolts, 2 seal washers and 2 nuts.

   Torque: Bolt A and nut A 

   11 N*m (112 kgf*cm, 8 ft.*lbf) 

   Bolt B 

   9.0 N*m (92 kgf*cm, 80 in.*lbf) 

Fig 19: Locating Cylinder Head Cover, Clamp Brackets, Bolts, Seal Washers And Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 3 clamps of the engine wire onto the clamp bracket.
5. Connect the ventilation hose No. 2.
6. Connect the ventilation hose.

1. Install the 4 ignition coils with the 4 bolts.

   Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

2. Install the engine wire with the 2 nuts.

   Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

   Fig 20: Locating Engine Wire Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the 4 ignition coil connectors.

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 21: Locating Engine Mounting Insulator RH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the oil reservoir bracket No. 1 with the 2 bolts.

   Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

Fig 22: Locating Oil Reservoir Bracket No. 1

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the generator assembly (See INSTALLATION ).

1. Install the vane pump assembly (See INSTALLATION ).

1. Add the engine coolant (See COOLANT ).

Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

1. Check for the engine coolant leakage (See COOLING SYSTEM ).

1. Install the cylinder head cover No. 2 with the 2 nuts and 2 clips.

   Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)