Timing Chain - Installation

1. Install chain tensioner slipper

2. Install no. 1 chain tensioner assembly

3. Install chain sub-assembly

4. Install no. 2 chain vibration damper

5. Install no. 1 idle gear shaft

6. Install timing gear case or timing chain case oil seal

7. Install timing chain or belt cover sub-assembly

8. Install vvt sensor

9. Install camshaft timing oil control valve assembly

10. Install cylinder head cover sub-assembly lh

11. Install cylinder head cover sub-assembly

12. Install ignition coil assembly

13. Install intake air surge tank

14. Install oil pan sub-assembly

15. Install oil strainer sub-assembly

16. Install no. 2 oil pan sub-assembly

17. Install crankshaft pulley

18. Install no. 1 idler pulley sub-assembly

19. Install no. 2 idler pulley sub-assembly

20. Install v-ribbed belt tensioner assembly

21. Install cooler compressor assembly

22. Install generator assembly

23. Install vane pump assembly

24. Install water inlet

25. Install oil level gauge guide

26. Install air cleaner assembly

27. Connect no. 2 ventilation hose

28. Install fluid coupling assembly

29. Install fan and generator v belt

30. Fully tighten fluid coupling assembly

31. Install radiator support seal upper

32. Install battery

33. Install differential carrier assembly front

34. Install power steering link assembly

35. Add engine oil

36. Add engine coolant

37. Check for engine oil leaks

38. Check for engine coolant leaks

39. Install v-bank cover

40. Inspect ignition timing

​

1. While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration.

2. While turning the stopper plate of the tensioner counterclockwise, insert a bar of φ3.5 mm (0.138 in.) into the holes on the stopper plate and tensioner to fix the stopper plate.

3. Install the chain tensioner with the 2 bolts.

   Torque:

   10 N*m{102 kgf*cm, 7 ft.*lbf}

1. Set the No. 1 cylinder to the TDC / compression.
   

   1. Align the timing marks of the camshaft timing gears and bearing caps.

   3. Install the crankshaft pulley set bolt, and turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block.

2. Align the mark link (yellow) with the timing mark of the crankshaft timing gear.

3. Align the mark links (orange) with the timing marks of the camshaft timing gears, and install the chain.

1. Instal the 2 No. 2 chain vibration dampers.

1. Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.

2. Temporarily install the No. 1 idle gear shaft and No. 1 idle gear with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear shaft with the knock pin groove of the cylinder block.

   NOTICE:

   Be careful of the idle gear direction.

3. Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.

   Torque:

   60 N*m{612 kgf*cm, 44 ft.*lbf}

4. Remove the bar from the chain tensioner.

1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge.

   SST

   09226-10010
   

2. Apply MP grease to the oil seal lip.

1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.

2. Install a new O-ring to the LH cylinder head as shown in the illustration.

3. Apply a continuous bead of seal packing (diameter 3.0 to 4.0 mm (0.12 to 0.16 in.)) to 4 locations as shown in the illustration.

   Seal packing:

   Part No. 08826-00080 or equivalent
   

4. Apply a continuous bead of seal packing (diameter 3.0 to 4.0 mm (0.12 to 0.16 in.)) to the timing chain cover as shown in the illustration.

   Seal packing:

   Water pump part:

   Part No. 08826-00100 or equivalent
   

   Other part:

   Part No. 08826-00080 or equivalent
   

   NOTICE:

   1. Install the timing chain cover within 3 minutes after applying seal packing. After installing it, the timing chain cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.
      
   2. Do not apply seal packing to the "A" as shown in the illustration.
      

5. Align the key way of the oil pump drive rotor with the rectangular portion of the crankshaft timing gear, and slide the timing chain cover into place.

6. Install the timing chain cover with the 15 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

   Torque:

   23 N*m{235 kgf*cm, 17 ft.*lbf}

   NOTICE:

   1. Pay attention not to wrap the chain and slipper over the timing chain cover seal line.
      
   2. After installing the timing chain cover, install the water pump within 15 minutes.
      

   HINT:

   Each bolt length is as follows:

   A: 25 mm (0.98 in.)

   B: 55 mm (2.17 in.)

1. LH bank side VVT sensor.
   

   1. Apply a light coat of engine oil to an O-ring of the VVT sensor.

   2. Install the VVT sensor with the bolt.

      Torque:

      8.0 N*m{82 kgf*cm, 71 in.*lbf}

   3. Connect the VVT sensor connector.

   5. Connect the water by-pass hoses No. 4 and No. 5.

2. RH bank side VVT sensor.
   

   1. Apply a light coat of engine oil to an O-ring of the VVT sensor.

   2. Install the VVT sensor with the bolt.

      Torque:

      8.0 N*m{82 kgf*cm, 71 in.*lbf}

   3. Connect the VVT sensor connector.

1. Insert the camshaft timing oil control valves to each cylinder head, and tighten the 2 bolts.

   Torque:

   10 N*m{102 kgf*cm, 7 ft.*lbf}

1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.

2. Apply adhesive to the threads of the ventilation valve.

   Adhesive:

   Part No. 08833-00070, THREE BOND 1324 or equivalent
   

3. Install the ventilation valve to the cylinder head cover.

   Torque:

   27 N*m{275 kgf*cm, 20 ft.*lbf}

4. Apply a continuous bead of seal packing (diameter: 2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head and timing chain cover as shown in the illustration.

   Seal packing:

   Part No. 08826-00080 or equivalent
   

   NOTICE:

   Install the cylinder head cover within 3 minutes after applying seal packing. After installing it, the cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.

5. Install the gasket to the cylinder head cover.

6. Install the seal washers to the bolts.

7. Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

   Torque:

   For bolt A:

   10 N*m{102 kgf*cm, 7 ft.*lbf}

   For bolt B:

   9.0 N*m{92 kgf*cm, 80 in.*lbf}

   For nut:

   9.0 N*m{92 kgf*cm, 80 in.*lbf}

1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.

2. Apply a continuous bead of seal packing (diameter: 2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head and timing chain cover as shown in the illustration.

   Seal packing::

   Part No. 08826-00080 or equivalent
   

   NOTICE:

   Install the cylinder head cover within 3 minutes after applying seal packing. After installing it, the cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.

3. Install the gasket to the cylinder head cover.

4. Install the seal washers to the bolts.

5. Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

   Torque:

   For bolt A:

   10 N*m{102 kgf*cm, 7 ft.*lbf}

   For bolt B:

   9.0 N*m{92 kgf*cm, 80 in.*lbf}

   For nut:

   9.0 N*m{92 kgf*cm, 80 in.*lbf}

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

1. Install a new gasket to the intake air surge tank.

2. Using the socket hexagon wrench 8, install the intake air surge tank with the 4 bolts.

   Torque:

   28 N*m{286 kgf*cm, 21 ft.*lbf}

3. Install the 2 intake air surge tank nuts.

   Torque:

   28 N*m{286 kgf*cm, 21 ft.*lbf}

4. Install the 2 surge tank stays with the 4 bolts.

   Torque:

   21 N*m{214 kgf*cm, 15 ft.*lbf}

5. Install the oil baffle plate with the bolt.

   Torque:

   9.0 N*m{92 kgf*cm, 80 in.*lbf}

6. Install the throttle body bracket with the 2 bolts.

   Torque:

   21 N*m{214 kgf*cm, 15 ft.*lbf}

7. Install the 3 wire harness clamps and hose clamp.

8. Connect the throttle body with motor connector.

9. Connect the 2 VSV connectors.

10. Connect the ventilation hose.

11. Connect the fuel vapor feed hose.

12. Connect the 2 water by-pass hoses.

1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan.

2. Install a new O-ring to the oil pump.

3. Apply a continuous bead of seal packing (diameter: 3 to 4 mm (0.12 to 0.16 in.)) to the oil pan as shown in the illustration.

   Seal packing:

   Part No. 08826-00080 or equivalent
   

   NOTICE:

   Install the oil pan within 3 minutes after applying seal packing. After installing it, the oil pan bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.

4. Install the oil pan with the 17 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

   Torque:

   For bolt A:

   21 N*m{214 kgf*cm, 15 ft.*lbf}

   For bolt B:

   21 N*m{214 kgf*cm, 15 ft.*lbf}

   For bolt C:

   10 N*m{102 kgf*cm, 7 ft.*lbf}

   For nut:

   21 N*m{214 kgf*cm, 15 ft.*lbf}

   HINT:

   Each bolt length is as follows:

   A: 25 mm (0.98 in.)

   B: 45 mm (1.77 in.)

   C: 14 mm (0.55 in.)

5. Install the 4 housing bolts.

   Torque:

   37 N*m{377 kgf*cm, 27 ft.*lbf}

6. Install the flywheel housing under cover.

1. Install a new gasket and the oil strainer with the 2 nuts.

   Torque:

   9.0 N*m{92 kgf*cm, 80 in.*lbf}

1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pan and No. 2 oil pan.

2. Apply a continuous bead of seal packing (diameter 3: to 4 mm (0.12 to 0.16 in.)) as shown in the illustration.

   Seal packing:

   Part No. 08826-00080 or equivalent
   

   NOTICE:

   Install the No. 2 oil pan within 3 minutes after applying seal packing. After installing it, the No. 2 oil pan bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.

3. Install the No. 2 oil pan with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

   Torque:

   10 N*m{102 kgf*cm, 7 ft.*lbf}

1. Using SST, install the pulley set bolt.

   SST

   09213-54015 (91651-60855)
   09330-00021
   

   Torque:

   250 N*m{2,549 kgf*cm, 184 ft.*lbf}

1. Install the idler pulley with the bolt.

   Torque:

   54 N*m{551 kgf*cm, 40 ft.*lbf}

   HINT:

   "DOUBLE" is marked on the No. 1 idler pulley to distinguish it from the No. 2 idler pulley.

1. Install the 2 idler pulleys with the 2 bolts.

   Torque:

   39 N*m{398 kgf*cm, 29 ft.*lbf}

1. Temporarily install the V-ribbed belt tensioner with the 5 bolts.

2. Install the V-ribbed belt tensioner by tightening the bolt 1 and bolt 2 in the order shown in the illustration.

   Torque:

   36 N*m{367 kgf*cm, 27 ft.*lbf}

3. Tighten the other bolts.

   Torque:

   36 N*m{367 kgf*cm, 27 ft.*lbf}

   HINT:

   Each bolt length is as follows:

   A: 70 mm (2.76 in.)

   B: 33 mm (1.30 in.)

1. Install the cooler compressor assembly with the 4 bolts.

   Torque:

   25 N*m{255 kgf*cm, 18 ft.*lbf}

2. Connect the cooler compressor assembly connector.

3. Install the suction hose sub-assembly with the bolt.

   Torque:

   8.0 N*m{82 kgf*cm, 71 in.*lbf}

1. Install the generator assembly with the 2 bolts.

   Torque:

   43 N*m{438 kgf*cm, 32 ft.*lbf}

2. Install the wire harness clamp bracket with the 2 bolts.

   Torque:

   8.0 N*m{82 kgf*cm, 71 in.*lbf}

3. Connect the wire harness.
   

   1. Connect the wire harness to the terminal B and install the nut.

      Torque:

      9.8 N*m{100 kgf*cm, 7 ft.*lbf}

   2. Connect the connector to the generator assembly.

   3. Install the wire harness stay with the bolt.

      Torque:

      8.0 N*m{82 kgf*cm, 71 in.*lbf}

1. Install the vane pump with the 2 bolts.

   Torque:

   43 N*m{438 kgf*cm, 32 ft.*lbf}

   NOTICE:

   Do not hit the pulley to other parts when installing the vane pump.

2. Connect the P/S oil pressure switch connector.

1. Install a new O-ring to the water outlet pipe.

2. Install a new gasket to the water pump.

3. Apply soapy water to the O-ring.

4. Install the water inlet with the 5 bolts.

   Torque:

   9.0 N*m{92 kgf*cm, 80 in.*lbf}

5. Connect the 5 water by-pass hoses.

6. Connect the 2 radiator hoses.

7. Connect the 2 oil cooler hoses (with oil cooler).

1. Install a new O-ring to the oil level gauge guide.

2. Apply a light coat of engine oil to the O-ring.

3. Push in the oil level gauge guide end into the guide hole of the oil pan.

4. Install the oil level gauge guide with the bolt.

   Torque:

   9.0 N*m{92 kgf*cm, 80 in.*lbf}

5. Install the oil level gauge.

1. Install the air cleaner with the 2 bolts.

   Torque:

   8.0 N*m{82 kgf*cm, 71 in.*lbf}

2. Tighten the 2 hose clamps.

3. Install the 2 wire harness clamps.

4. Connect the mass air flow meter connector.

5. Connect the vacuum hose.

6. Connect the ventilation hose No. 2.

1. Put the fan pulley to the water pump.

2. Put the fan with fluid coupling and fan shroud together.

3. Temporarily install the 4 fluid coupling nuts.

4. Tighten the 2 fan shroud bolts and radiator reserve tank bolt.

   Torque:

   5.0 N*m{51 kgf*cm, 44 in.*lbf}

5. Connect the reserve tank hose.

6. Fasten the 2 oil cooler hoses with the hose clamp.

1. While turning the belt tensioner counterclockwise, align with its holes, and then insert a bar of 6 mm (0.24 in.) into the holes to fix the belt tensioner.

2. Install the V-ribbed belt.

3. While turning the belt tensioner counterclockwise, remove the bar.

4. If it is hard to install the V-ribbed belt, perform the following procedure.
   

   1. Put the V-ribbed belt on all parts except the P/S pump, as shown in the illustration.

   2. While releasing the belt tension by turning the belt tensioner counterclockwise, put the V-ribbed belt on the P/S pump.

1. Tighten the 4 fluid coupling bolts.

   Torque:

   21 N*m{214 kgf*cm, 15 ft.*lbf}

HINT:

(Click here)

HINT:

(Click here)

1. Fill with fresh engine oil.

   Capacity:

   Drain and refill with oil filter change	5.2 liters (5.5 US qts, 4.6 lmp. qts)
   Drain and refill without oil filter change	4.9 liters (5.2 US qts, 4.3 lmp. qts)
   Dry fill	6.0 liters (6.3 US qts, 5.3lmp. qts)

2. Reinstall the oil filler cap.

1. Slowly fill the system with engine coolant.

   Capacity:

   9.8 liters (10.4 Us qts, 8.6 Imp. qts)
   

   HINT:

   1. Use of improper coolants may damage the engine cooling system.
      
   2. Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).
      
   3. New Toyota vehicles are filled with Toyota Super Long Life Coolant (color is pink, premixed ethylene glycol concentration is approximately 50 % and freezing temperature is -35°C (-31°F)). When replacing the coolant, Toyota Super Long Life Coolant is recommended.
      
   4. Observe the coolant level inside the radiator by pressing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add the coolant.
      

   NOTICE:

   Do not substitute plain water for engine coolant.

2. Install the radiator cap securely.

3. Bleed the cooling system.
   

   1. Open the heater water valve while warming up the engine.

   2. Maintain the engine speed at 2,000 to 2,500 rpm and warm up the engine.

4. Stop the engine and wait until the coolant cools down.

5. Add coolant into the reservoir until the coolant level is FULL.

1. Fill the radiator with coolant and attach a radiator cap tester.

2. Pump it to 118 kPa (1.2 kgf/cm² 17.1 psi), then check for leakage.

1. Install the V-bank cover with the 2 nuts.

   Torque:

   7.5 N*m{76 kgf*cm, 66 in.*lbf}

NOTICE:

1. Turn all electrical systems OFF.
   

1. Operate the inspection when the cooling fan motor is turned OFF.
   

1. Warm up the engine.

2. When using the intelligent tester.
   

   1. Connect the intelligent tester to the DLC3.

   2. Select the following menu items: DIAGNOSIS / ENHANCED OBD ll / DATA LIST / IGN ADVANCE.

   3. Inspect the ignition timing during idling.

      Ignition timing:

      7 to 24°CA BTDC during idling (Transmission in neutral position)
      

   4. Check that the ignition timing advances immediately when the engine speed is increased.

3. When not using intelligent tester.
   

   1. Using SST, connect the terminals 13 (TC) and 4 (CG) of the DLC3.

      SST

      09843-18040
      

      NOTICE:

      Be sure not to connect the terminals wrongly. It causes breakage of the engine.

   2. Remove the air cleaner cap sub-assembly.

   4. Pull out the wire harness as shown in the illustration.

   5. Connect the tester probe of a timing light to the wire of the ignition coil connector for No. 1 cylinder.

      NOTICE:

      1. Use a timing light that detects the first signal.
         
      1. After checking, be sure to wrap the wire harness with tape.
         

   7. Inspect the ignition timing during idling.

      Ignition timing:

      8 to 12°CA BTDC during idling (Transmission in neutral position)
      

   8. Remove the SST from the DLC3.

   9. Inspect the ignition timing during idling.

      Ignition timing:

      7 to 24°CA BTDC during idling (Transmission in neutral position)
      

   10. Disconnect the timing light from the engine.

   11. Install the air cleaner cap sub-assembly.