Timing Belt - Installation

1. Install timing belt

2. Install no. 1 crankshaft position sensor plate

3. Install timing belt no. 1 cover

4. Install crankshaft damper sub-assembly

5. Install fan bracket sub-assembly

6. Install v-ribbed belt tensioner assembly

7. Install no. 2 timing belt cover sub-assembly

8. Install no. 3 timing belt cover sub-assembly lh

9. Install no. 2 timing chain or belt cover

10. Install oil cooler pipe

11. Install no. 2 idler pulley sub-assembly

12. Install compressor

13. Install generator assembly

14. Install vane pump assembly

15. Install fan with fluid coupling

16. Install fan and generator v belt

17. Install radiator support seal upper

18. Install air cleaner hose assembly

19. Install throttle body cover sub-assembly

20. Add engine coolant

21. Check for engine coolant leaks

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1. Check the No. 1 timing belt idler and No. 2 timing belt idler.
   

   1. Visually check the seal portion of the idler pulley for oil leakage.
      If leakage is found, replace the idler.

   2. Check that the idler turns smoothly.
      If necessary, replace the idler.

2. Check the water pump.
   

   1. Visually check the air hole and water hole for coolant leakage.
      If leakage is found, replace the water pump and timing belt.

   2. Turn the pulley, and check that the water pump bearing moves smoothly.
      If necessary, replace the water pump.

3. Remove any oil or water on the crankshaft pulley, oil pump pulley, water pump pulley, No. 1 idler and No. 2 idler, and keep them clean.

   NOTICE:

   Only wipe the pulleys; do not use any cleansing agent.

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

   1. Turn the hexagonal portion of the camshaft to align the timing marks of the camshaft timing pulleys and timing belt plates.

      HINT:

      By turning the camshaft timing pulleys clockwise as follows, installation of the timing pulleys will be easy:

      1/2 teeth turn for the left bank camshaft timing pulley

      1 tooth turn for the right bank camshaft timing pulley

   3. Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body.

5. Install the timing belt.
   

   1. Remove any oil or water on each pulley, and keep them clean.

      NOTICE:

      Only wipe the pulleys; do not use any cleansing agent.

   2. Face the front mark (arrow) on the timing belt forward.

   3. Put the timing belt on the crankshaft timing pulley.

      1. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
         

   4. Put the timing belt on the No. 2 idler.

   5. Put the timing belt on the camshaft timing pulley (LH bank).

      1. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley.
         

   6. Put the timing belt on the water pump pulley.

   7. Put the timing belt on the camshaft timing pulley (RH bank).

      1. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley.
         

   8. Put the timing belt on the No. 1 idler.

6. Set the belt tensioner.
   

   1. Using a press, slowly press in the push rod using 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) of pressure.

   2. Align the holes of the push rod and housing, and pass a 1.27 mm 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.

7. Install the belt tensioner.
   

   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 hexagon wrench from the chain tensioner.

8. Check the valve timing.
   

   1. Using the crankshaft damper bolt, slowly turn the crankshaft pulley 2 revolutions from the TDC to TDC.

      NOTICE:

      Always turn the crankshaft pulley clockwise.

   3. Check that each pulley is aligned with each timing mark as shown in the illustration.
      If the timing marks are not aligned, remove the timing belt and reinstall it.

   4. Remove the crankshaft damper bolt.

1. Install the sensor plate as shown in the illustration.

   NOTICE:

   Take care not to install it in a wrong direction.

1. Install the timing belt cover with the 4 bolts.

   Torque:

   7.5 N*m{80 kgf*cm, 66 in.*lbf}

1. Align the pulley set key with the key groove of the crankshaft damper.

2. Using SST and a hammer, tap in the crankshaft damper.

   SST

   09223-46011
   

3. Using SST, install the damper bolt.

   SST

   09213-70011 (09213-70020)
   09330-00021
   

   Torque:

   245 N*m{2,498 kgf*cm, 181 ft.*lbf}

1. Install the idler pulley with the 2 bolts and 2 nuts.

   Torque:

   For 12 mm head:

   16 N*m{160 kgf*cm, 12 ft.*lbf}

   For 14 mm head:

   32 N*m{326 kgf*cm, 24 ft.*lbf}

   HINT:

   Each bolt length is as follows:

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

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

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

   Torque:

   16 N*m{160 kgf*cm, 11 ft.*lbf}

   HINT:

   Use a bolt 106 mm (4.17 in.) in length.

1. Install the timing belt cover and fit the claws and pins into each part.

2. Install the timing belt cover with the 2 bolts.

   Torque:

   16 N*m{160 kgf*cm, 12 ft.*lbf}

   HINT:

   Use bolts 106 mm (4.17 in.) in length.

1. Install the timing belt cover sub-assembly with the 4 bolts.

   Torque:

   7.5 N*m{80 kgf*cm, 66 in.*lbf}

2. Install the camshaft position sensor connector and grommet to the timing belt cover.

1. Install the timing chain or belt cover with the nut and 3 bolts.

   Torque:

   7.5 N*m{80 kgf*cm, 66 in.*lbf}

1. Install the oil cooler pipe with the bolt and nut.

   Torque:

   7.5 N*m{80 kgf*cm, 66 in.*lbf}

2. Connect the 3 hoses.

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

   Torque:

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

1. Install the compressor with the stay, nut and 3 bolts.

   Torque:

   Bolt:

   47 N*m{475 kgf*cm, 34 ft.*lbf}

   Nut:

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

1. Install the generator with the bolt and 2 nuts.

   Torque:

   Bolt:

   39 N*m{400 kgf*cm, 29 ft.*lbf}

   Nut (M10):

   39 N*m{40 kgf*cm, 29 ft.*lbf}

   Nut (M8):

   16 N*m{158 kgf*cm, 11 ft.*lbf}

2. Connect the generator connector.

3. Connect the generator wire with the nut and rubber cap.

   Torque:

   9.8 N*m{100 kgf*cm, 86 in.*lbf}

4. Install the generator wire clamp to the cord clip on the generator.

1. Install the vane pump assembly with the nut and 2 bolts.

   Torque:

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

1. Install the fan pulley to the engine.

2. Put the fan with fluid coupling and fan shroud together into the engine room.

3. Install the fan shroud with the 3 bolts.

   Torque:

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

4. Install the fan with fluid coupling with the 4 nuts.

   Torque:

   29 N*m{296 kgf*cm, 21 ft.*lbf}

1. Set the V belt onto every parts except the No. 2 idler pulley, as shown in the illustration.

2. Loosen the V belt by turning the belt tensioner counterclockwise.

3. Set the V belt to the No. 2 idler pulley.

4. After installing a new belt, check that the mark is within the B range as shown in the illustration.

1. Install the throttle body cover sub-assembly with the 2 nuts.

   Torque:

   7.5 N*m{80 kgf*cm, 66 in.*lbf}

1. Slowly fill the system with engine coolant.

   Capacity:

   12.3 liters (13.0 US qts, 10.8 lmp. 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.