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Timing Gear: Installation

  1. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. Raise the chain.
    2. Hold the hexagonal portion of the intake camshaft with a wrench and turn it slightly counterclockwise to release the chain.
    3. Align the paint mark with the matchmark to install the chain.
      NOTE: Do not turn the intake camshaft more than necessary.
      Fig 1: Identifying Matchmark To Chain
      G06008712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Align the straight pin on the No. 2 camshaft with the pin hole in the camshaft timing exhaust gear assembly and install the camshaft timing exhaust gear assembly to the No. 2 camshaft.
      NOTE:
      • If the straight pin cannot be aligned with the pin hole, hold the hexagonal portion of the No. 2 camshaft with a wrench and turn it slightly to install the gear.
      • Do not turn the No. 2 camshaft more than necessary.
      • Do not forcibly push on the tip of the straight pin with the camshaft timing exhaust gear assembly.
      Fig 2: Identifying Straight Pin And Key Groove
      G04974660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST and a wrench, hold the hexagonal portion of the No. 2 camshaft and install the camshaft timing exhaust gear assembly to the No. 2 camshaft.

      SST 09249-37010 

      Torque: without SST 

      54 N*m (551 kgf*cm, 40 ft.*lbf) 

      with SST 

      39 N*m (397 kgf*cm, 29 ft.*lbf) 

      Fig 3: Installing Camshaft Timing Exhaust Gear Assembly
      G06008714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • This torque value can be obtained by using a torque wrench with a fulcrum length of 260 mm (10.24 in.) and SST of 100 mm (3.94 in.) (See REPAIR INSTRUCTION ).
      • This torque value is effective when SST is parallel to the torque wrench.
  2. INSTALL NO. 2 CHAIN VIBRATION DAMPER 
    1. Using SST, install the No. 2 chain vibration damper with the 2 bolts.

      SST 09961-00950 

      Torque: without SST 

      10 N*m (102 kgf*cm, 7 ft.*lbf) 

      with SST 

      5.5 N*m (56 kgf*cm, 48 in.*lbf) 

      Fig 4: Installing No. 2 Chain Vibration Damper
      G06008715Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • This torque value can be obtained by using a torque wrench with a fulcrum length of 180 mm (7.09 in.) and SST of 150 mm (5.91 in.) (See REPAIR INSTRUCTION ).
      • This torque value is effective when SST is parallel to the torque wrench.
  3. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY  (See REASSEMBLY )
  4. SET NO. 1 CYLINDER TO TDC/COMPRESSION 
    1. Turn the crankshaft clockwise 360° to set the No. 1 cylinder to TDC/compression and align the matchmark (cutout) with the "0" mark on the timing chain (belt) cover.
    2. Check that the matchmark on each camshaft timing gear is positioned as shown in the illustration.
  5. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY  (See REASSEMBLY )
  6. INSTALL IGNITION COIL ASSEMBLY  (See INSTALLATION )
  7. INSTALL RADIO SETTING CONDENSER  (See INSTALLATION )
    Fig 5: Identifying Matchmark On Timing Chain Cover
    G06008716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL WIRE HARNESS 
    1. Install the air tube with the 2 bolts (*2).

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    2. Connect the 9 connectors and install the wire harness with the 2 bolts (*1) and 2 clamps.

      Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 

  9. INSTALL NO. 2 VENTILATION HOSE 
  10. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY  (See INSTALLATION )
    Fig 6: Locating Air Tube With Bolts
    G06008698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. CONNECT UNION TO CONNECTOR TUBE HOSE  (See INSTALLATION )
  12. INSTALL NO. 2 CYLINDER HEAD COVER  (See INSTALLATION )
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