Install the No. 1 belt idler with the 3 bolts.

• Момент затяжки:
• for bolt A:
• 44 N*m{ 449 kgf*cm, 32 ft.*lbf}
• for bolt B, C:
• 19 N*m{ 195 kgf*cm, 14 ft.*lbf}

• УКАЗАНИЕ:

The bolt lengths for bolt A, B and C as follows.

Bolt C is combined with the No. 1 timing belt idler.

• Standard Bolt:

• Item	Length
  A	76.5 mm (3.01 in.)
  B	42.9 mm (1.69 in.)
  C	41.3 mm (1.63 in.)

Using the crankshaft pulley bolt, align the groove of the crankshaft pulley with the timing pointer by turning the crankshaft clockwise.

Text in Illustration

*1	Timing Mark
	Turn

• ПРИМЕЧАНИЕ:

• Do not turn the crankshaft pulley counterclockwise.

Set the timing and drive pulleys at each position.

• ПРИМЕЧАНИЕ:

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

Install the timing belt to the crankshaft timing and timing belt idlers.

Using SST, slightly turn the injection pump drive pulley clockwise. Install the timing belt to the pulley, and align the timing marks of the drive pulley and timing belt case.

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

Using SST, slightly turn the camshaft timing pulley clockwise. Install the timing belt to the timing pulley, and align the timing marks of the timing pulley and timing belt case.

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

Check that the timing belt has tension between the injection pump drive and camshaft timing pulleys.

Install the timing belt to the No. 1 timing belt idler.

Loosen the No. 1 timing belt idler bolt (A), and stretch the timing belt.

Slowly turn the crankshaft pulley.

• ПРИМЕЧАНИЕ:

• Always turn the crankshaft clockwise.

Tighten the No. 1 timing belt idler bolt.

• Момент затяжки:
• 44 N*m{ 449 kgf*cm, 33 ft.*lbf}

Slowly turn the crankshaft pulley 2 revolutions from TDC to TDC.

• ПРИМЕЧАНИЕ:

• Always turn the crankshaft clockwise.

Check that the timing marks for each pulley align as shown in the illustration.

If the timing marks do not align, remove the timing belt and reinstall it.

Install the timing belt guide with the cup side facing outward.

Install 2 new gaskets to the timing belt cover.

Install the timing belt cover with the 11 bolts and washers.

• Момент затяжки:
• for bolt A:
• 8.5 N*m{ 85 kgf*cm, 75 ft.*lbf}
• except bolt A:
• 11 N*m{ 107 kgf*cm, 8 ft.*lbf}

Install the idle pulley bracket with the 2 bolts.

• Момент затяжки:
• 29 N*m{ 300 kgf*cm, 22 ft.*lbf}

Align the key groove of the pulley with the pulley set key, and slide the pulley onto the crankshaft to install it.

Using SST, install the pulley bolt.

• SST
• 09213-54015(91651-60855)
  09330-00021

• Момент затяжки:
• 235 N*m{ 2396 kgf*cm, 173 ft.*lbf}

Install the vane pump drive pulley and cooler compressor drive pulley with the 4 bolts.

• Момент затяжки:
• 19 N*m{ 194 kgf*cm, 14 ft.*lbf}

Install the fan shroud (See page ).

Warm up the engine.

When using the intelligent tester:

When not using an intelligent tester:

Start the engine.

Fully depress the accelerator pedal.

Check the maximum speed.

• Maximum engine speed:
• 4850 to 4950 rpm

If there is premature parting:

If the belt teeth are cracked or damaged, check if either camshaft is locked.

If there is noticeable wear or cracks on the belt face, check if there are nicks on the side of the idler pulley lock and water pump.

If there is wear or damage to only one side of the belt, check the belt guide and the alignment of each pulley.

If there is noticeable wear on the belt teeth:

If necessary, replace the timing belt.

Visually check the seal portion of the No. 1 timing belt idler for oil leakage.

Text in Illustration

*1	Seal
	Turn

If leakage is found, replace the No. 1 timing belt idler sub-assembly.

Check that the No. 1 timing belt idler turns smoothly. If necessary, replace the No. 1 timing belt idler sub-assembly.

Measure the free length of the tension spring.

• Standard free length:
• 44.4 to 45.4 mm (1.75 to 1.79 in.)

If the free length is not as specified, replace the idler tension spring.

Measure the tension of the tension spring at the installed length.

• Standard tension:
• 53 to 59 N (5.40 to 6.02 kgf, 11.9 to 13.3 lbf) at 52.1 mm (2.05 in.)

If the installed tension is not as specified, replace the idler tension spring.

Remove the fan shroud (See page ).

Remove the 4 bolts, vane pump drive pulley and cooler compressor drive pulley.

Using SST, remove the pulley bolt.

• SST
• 09213-54015(91651-60855)
  09330-00021

Using SST, remove the pulley.

• SST
• 09950-50013(09951-05010,09952-05010,09953-05020,09954-05021)
  09950-60010(09951-00490)
  09950-40011(09957-04010)

Remove the 2 bolts and Idle pulley bracket.

Remove the 11 bolts, washers, timing belt cover, and 2 gaskets.

Remove the timing belt guide.

Using the crankshaft pulley bolt, align the groove of the crankshaft pulley with the timing pointer by turning the crankshaft clockwise.

Text in Illustration

*1	Timing Mark
	Turn

Check that the timing marks of the camshaft timing pulley and No. 2 timing belt cover are aligned.

If not, turn the crankshaft 1 revolution (360°).

Turn the crankshaft 90° counterclockwise, and align the timing mark of the crankshaft timing pulley with the protrusion of the timing belt case.

Text in Illustration

Turn

• ПРИМЕЧАНИЕ:

• If the timing belt is disengaged, having the crankshaft timing pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when removing the camshaft timing pulley, and camshaft causing damage. Therefore, always set the crankshaft pulley is removed at the correct angle.

Loosen the No. 1 timing belt idler bolt (A), and shift the idler to the left as far as possible.

Text in Illustration

	Pry
	Move

Tighten the No. 1 timing belt idler bolt (A), and then relieve the timing belt tension.

Remove the timing belt.

Remove the 2 bolts (A and B).

Loosen the bolt (C), and remove the No. 1 timing belt idler.

Disconnect the sensor connector.

Detach the wire harness clamp.

Loosen the hose clamp and remove the resonator with air cleaner cap.

Detach the 4 hook clamps, and then remove the air cleaner cap and resonator with air cleaner cap.

Loosen the hose clamp and remove the 2 bolts and intake pipe.

Remove the 9 bolts, nut, cylinder head cover and gasket.

Turn the crankshaft pulley and align its groove with the timing pointer.

Check that the valve lifters for the No. 1 cylinder are loose and the valve lifters for the No. 4 cylinder are tight.

If not, turn the crankshaft 1 revolution (360°) and align the mark as above.

Check only the valves indicated in the illustration.

Turn the crankshaft 1 revolution (360°) and align the mark as above.

Check only the valves indicated in the illustration.

Remove the adjusting shim.

Turn the crankshaft so that the cam lobe of the camshaft on the valve being adjusted points upward.

Using SST, press down the valve lifter.

• SST
• 09248-64011

Position the notch of the valve lifter so that it faces the exhaust manifold side.

Remove the adjusting shim with a screwdriver and magnet hand.

Determine the replacement adjusting shim size according to the formula and charts below.

Install a new adjusting shim.

Recheck valve clearance.

Remove any old packing (FIPG material).

Apply seal packing to the cylinder head as shown in the illustration.

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

Install the gasket to the cylinder head cover.

Install the cylinder head cover with the 9 bolts and nut. Uniformly tighten the bolts and nut in several steps.

• Момент затяжки:
• 12 N*m{ 122 kgf*cm, 9 ft.*lbf}

Install the intake pipe with the 2 bolts.

• Момент затяжки:
• 18 N*m{ 184 kgf*cm, 13 ft.*lbf}

Tighten the intake pipe clamp.

• Момент затяжки:
• 6.0 N*m{ 61 kgf*cm, 53 in.*lbf}

Вставьте петли крышки воздушного фильтра и шланг в корпус воздушного фильтра, а затем закрепите 4 откидных защелки.

Установите крышку воздушного фильтра и закрепите ее зажимом.

• Момент затяжки:
• 5,0 N*m{ 51 kgf*cm, 44 in.*lbf}

Закрепите зажим жгута проводов.

Подсоедините 2 зажима и разъем.

Warm up the engine.

When using the intelligent tester:

When not using an intelligent tester:

Start the engine.

Fully depress the accelerator pedal.

Check the maximum speed.

• Maximum engine speed:
• 4850 to 4950 rpm

Установите поликлиновой ремень.

Отрегулируйте натяжение поликлинового ремня с помощью болта A.

Затяните болты B и C.

• Момент затяжки:
• для болта C:
• 69 N*m{ 704 kgf*cm, 51 ft.*lbf}
• для болта B:
• 18 N*m{ 184 kgf*cm, 13 ft.*lbf}

Проверьте натяжение поликлинового ремня .

Установите поликлиновой ремень.

Отрегулируйте натяжение поликлинового ремня с помощью болта B.

Затяните гайку А.

• Момент затяжки:
• 39 N*m{ 400 kgf*cm, 29 ft.*lbf}

Проверьте натяжение поликлинового ремня .

Установите поликлиновой ремень.

Отрегулируйте натяжение поликлинового ремня с помощью стержня.

Затяните болт А и гайку В.

• Момент затяжки:
• Для болта:
• 48 N*m{ 489 kgf*cm, 35 ft.*lbf}
• Для гайки:
• 64 N*m{ 653 kgf*cm, 47 ft.*lbf}

Проверьте натяжение поликлинового ремня .

Install the air cleaner case with the 3 bolts.

• Момент затяжки:
• 12 N*m{ 122 kgf*cm, 9 ft.*lbf}

Вставьте петли крышки воздушного фильтра и шланг в корпус воздушного фильтра, а затем закрепите 4 откидных защелки.

Установите крышку воздушного фильтра и закрепите ее зажимом.

• Момент затяжки:
• 5,0 N*m{ 51 kgf*cm, 44 in.*lbf}

Закрепите зажим жгута проводов.

Подсоедините 2 зажима и разъем.

Install the front fender apron seal with the 4 clips.

Hook the engine under cover to the vehicle body as shown in the illustration.

Install the 4 bolts.

• Момент затяжки:
• 29 N*m{ 296 kgf*cm, 21 ft.*lbf}

Install the front bumper cover lower with the 5 bolts and clip.

• Момент затяжки:
• 8.0 N*m{ 82 kgf*cm, 71 in.*lbf}

Remove the clip, 5 bolts and front bumper cover lower.

Remove the 4 bolts.

Unhook the engine under cover from the vehicle body as shown in the illustration.

Remove the 4 clips and fender apron seal.

Disconnect the sensor connector.

Detach the wire harness clamp.

Loosen the hose clamp and remove the resonator with air cleaner cap.

Detach the 4 hook clamps, and then remove the air cleaner cap and resonator with air cleaner cap.

Remove the 3 bolts and air cleaner case.

Loosen bolt and nut, and remove the V belt.

Loosen nut and adjusting bolt, and remove the V belt.

Loosen 2 bolts.

Loosen adjusting bolt, and remove the V belt.

Visually check the belt for cracks, oiliness or wear. Check that the belt does not touch the bottom of the pulley groove.

If necessary, replace the belt.

Check the vane pump V belt deflection by pressing on the belt at the point indicated in the illustration with 98 N (10 kgf, 22 lbf) of force.

• Standard Deflection:

• Item	Specified Condition
  New belt	8 to 10 mm (0.314 to 0.393 in.)
  Used belt	10 to 15 mm (0.393 to 0.590 in.)

Text in Illustration

*1	Vane Pump Pulley
*2	Crankshaft Pulley
	Measuring Point for Belt Tension

Reference:

Using a belt tension gauge, check the cooler compressor V belt tension.

• Standard Tension:

• Item	Specified Condition
  New belt	441 to 539 N (45 to 55 kgf, 99.1 to 121.2 lbf)
  Used belt	196 to 343 N (20 to 35 kgf, 44.1 to 77.1 lbf)

Check the cooler compressor V belt deflection by pressing on the belt at the point indicated in the illustration with 98 N (10 kgf, 22 lbf) of force.

• Standard Drive Deflection:

• Item	Specified Condition
  New belt	11 to 15 mm (0.433 to 0.590 in.)
  Used belt	15 to 20 mm (0.590 to 0.787 in.)

Text in Illustration

*1	Cooler Compressor
*2	Idle Pulley
*3	Crankshaft Pulley
	Measuring Point for Belt Tension

Reference:

Using a belt tension gauge, check the cooler compressor V belt tension.

• Standard Tension:

• Item	Specified Condition
  New belt	372 to 608 N (38 to 62 kgf, 83.6 to 136.7 lbf)
  Used belt	196 to 392 N (20 to 40 kgf, 44.1 to 88.1 lbf)

Check the fan and generator V belt deflection by pressing on the belt at the point indicated in the illustration with 98 N (10 kgf, 22 lbf) of force.

• Standard Deflection:

• Item	Specified Condition
  New belt	7.0 to 10 mm (0.276 to 0.393 in.)
  Used belt	10 to 14 mm (0.393 to 0.551 in.)

Text in Illustration

*1	Water Pump Pulley
*2	Generator
*3	Crankshaft Pulley
	Measuring Point for Belt Tension

Reference:

Using a belt tension gauge, check the fan and generator V belt tension.

• Standard Tension:

• Item	Specified Condition
  New belt	441 to 539 N (45 to 55 kgf, 99.1 to 121.2 lbf)
  Used belt	196 to 343 N (20 to 35 kgf, 44.1 to 77.1 lbf)