Timing Chain Installation

Set the crankshaft key in the left horizontal position.

Turn the cutout of the drive shaft so that it faces upward.

Align the yellow mark links with the timing marks of each gear as shown in the illustration.

Install the sprockets onto the crankshaft and oil pump shaft with the chain wrapped on the gears.

Temporarily tighten the oil pump drive shaft sprocket with the nut.

Insert the damper spring into the adjusting hole, and then install the chain tensioner plate with the bolt.

Torque:

12 N*m{122 kgf*cm, 9 ft.*lbf}

Align the adjusting hole of the oil pump drive shaft sprocket with the groove of the oil pump.

Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, and then tighten the nut.

Torque:

29.5 N*m{301 kgf*cm, 22 ft.*lbf}

Install the chain vibration damper with the 2 bolts.

Torque:

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

Set the No. 1 cylinder to TDC/compression.

1. Turn the camshafts with a wrench (using the hexagonal lobe) to align the timing marks of the camshaft timing gear with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration.
   





2. Using the crankshaft pulley bolt, turn the crankshaft to position the key on the crankshaft upward.
   

Install the chain onto the crankshaft timing sprocket with the gold or orange mark link aligned with the timing mark on the crankshaft.

Using SST and a hammer, tap in the crankshaft timing sprocket.

SST

09309-37010

Align the gold or yellow links with each timing mark located on the camshaft timing gear and sprocket, then install the chain.

Install the chain tensioner slipper with the bolt.

Torque:

19 N*m{194 kgf*cm, 14 ft.*lbf}

Install the timing chain guide with the bolt.

Torque:

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

Install the sensor plate with the "F" mark facing forward.

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

Apply seal packing (Diameter 4.0 to 4.5 mm (0.157 to 0.177 in.)) as shown in the illustration.

Seal packing:

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

NOTICE:

1. Remove any oil from the contact surface.
   

1. Install the chain cover within 3 minutes of applying seal packing.
   

1. Do not add engine oil for at least 2 hours after installing the chain cover.
   

Apply a continuous bead of seal packing as shown in the illustration.

Seal packing:

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

NOTICE:

1. Remove any oil from the contact surface.
   

1. Install the chain cover within 3 minutes of applying seal packing.
   

1. Do not add engine oil for at least 2 hours after installing the chain cover.
   
   
   
   
   
   

Install the timing chain cover with the 12 bolts and 2 nuts.

Torque:

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

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

55 N*m{561 kgf*cm, 41 ft.*lbf} for bolt C

11 N*m{112 kgf*cm, 8 ft.*lbf} for nut

HINT:

Bolt length:

Using an E10 "torx" socket, install the stud bolt for the V-ribbed belt tensioner.

Torque:

21.5 N*m{219 kgf*cm, 16 ft.*lbf}

Release the ratchet pawl, then fully push in the plunger and hook the hook to the pin so that the plunger is in the position shown in the illustration.

Install a new gasket and the chain tensioner with the 2 nuts.

Torque:

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

NOTICE:

When installing the chain tensioner, set the hook again if the hook releases the plunger.

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

Torque:

59.5 N*m{607 kgf*cm, 44 ft.*lbf}

NOTICE:

Do not lift the engine more than necessary.

Install the engine mounting bracket RH with the 3 bolts.

Torque:

55 N*m{561 kgf*cm, 41 ft.*lbf}

Using SST, fix the pulley in place and tighten the bolt.

SST

09213-54015(91651-60855)
09330-00021

Torque:

180 N*m{1,835 kgf*cm, 133 ft.*lbf}

Turn the crankshaft counterclockwise, then disconnect the plunger knock pin from the hook.

Turn the crankshaft clockwise, then check that the plunger is extended.

Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.

Apply a continuous bead of seal packing (Diameter 3.0 to 4.0 mm (0.118 to 0.157 in.)) as shown in the illustration.

Seal packing:

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

NOTICE:

1. Remove any oil from the contact surface.
   

1. Install the oil pan within 3 minutes of applying seal packing.
   

1. Do not add engine oil for at least 2 hours after installing the oil pan.
   

Install the oil pan to the cylinder block.

Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration.

Torque:

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

Place a transmission jack underneath the engine, then put a wooden block on the jack.

Remove the chain block and sling device.

Remove the No. 1 and No. 2 engine hangers.

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

Install the sensor with the bolt.

Torque:

9.0 N*m{90 kgf*cm, 80 in.*lbf}

Install the wire harness clamp.

Install the connector clamp.

Connect the sensor connector.

Confirm that the wire harness of the sensor is secured to the wire harness clamp bracket through the back of the rib of the timing chain cover.

Remove any old packing material from the contact surface.

Apply seal packing to the 2 locations shown in the illustration.

Seal packing:

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

NOTICE:

1. Remove any oil from the contact surface.
   

1. Install the oil pan within 3 minutes of applying seal packing.
   

1. Do not add engine oil for at least 2 hours after installing the oil pan.
   

Install the cylinder head cover with the 8 bolts and 2 nuts.

Torque:

11 N*m{112 kgf*cm, 8 ft.*lbf} for bolt A

14 N*m{143 kgf*cm, 10 ft.*lbf} for bolt B

11 N*m{112 kgf*cm, 8 ft.*lbf} for nut

Install the 2 engine wires with the 2 bolts.

Torque:

8.4 N*m{86 kgf*cm, 74 in.*lbf}

Connect the clamp of the engine wire (labeled B).

Connect the 2 ventilation hoses to the cylinder head cover.

Install the 4 ignition coils with the 4 bolts.

Torque:

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

Connect the 4 ignition coil connectors.

Install the idler bracket with the 2 bolts.

Torque:

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

Install the engine mounting insulator RH with the 4 bolts and 2 nuts.

Torque:

95 N*m{969 kgf*cm, 70 ft.*lbf} for bolt

95 N*m{969 kgf*cm, 70 ft.*lbf} for nut A

52 N*m{530 kgf*cm, 38 ft.*lbf} for nut B

Install the engine mounting insulator FR with the 2 bolts.

Torque:

95 N*m{969 kgf*cm, 70 ft.*lbf}

Install the through bolt and nut.

Torque:

145 N*m{1,479 kgf*cm, 107 ft.*lbf}

HINT:

Install the bolt which is used to secure the front engine mounting bracket.

Install the radiator reservoir with the 2 bolts.

Torque:

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

Confirm that the wire harness of the crankshaft position sensor is secured to the wire harness clamp bracket through the back of the rib of the timing chain cover.

Install the generator with the 2 bolts.

Torque:

21 N*m{215 kgf*cm, 16 ft.*lbf}for bolt A

52 N*m{530 kgf*cm, 38 ft.*lbf}for bolt B

Install the wire harness clamp.

Install the wire harness clamp bracket with the bolt.

Torque:

8.4 N*m{85 kgf*cm, 74 in.*lbf}

Connect the generator wire with the nut.

Torque:

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

Install the terminal cap.

Connect the generator connector.

Using SST and 19 mm socket wrench, loosen the V-ribbed belt tensioner arm clockwise, then install the fan and generator V belt.

SST

09216-42010

NOTICE:

1. Be sure to connect SST and the tools so that they are in line during use.
   
2. When retracting the tensioner, turn it clockwise slowly for 3 seconds or more. Do not apply force rapidly.
   
3. After the tensioner is fully retracted, do not apply force any more than necessary.
   

Install the reinforcement RH with the 4 bolts.

Torque:

96 N*m{979 kgf*cm, 71 ft.*lbf}

Using a vernier caliper, measure the free length of the compression spring.

Minimum length:

41.5 mm (1.634 in.)

Install a new gasket by hand so that its surface is flush with the exhaust manifold.

NOTICE:

1. Make sure the gasket is facing the correct direction.
   
2. Do not reuse the removed gasket.
   
3. Do not push in the gasket while installing the front exhaust pipe.
   

Install the front exhaust pipe with the 2 compression springs and 2 bolts.

Torque:

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

Clean and install the oil drain plug with a new gasket.

Torque:

40 N*m{408 kgf*cm, 30 ft.*lbf}

Add new oil.

Standard capacity:

Item	Standard Condition
Drain and refill with oil filter change	4.3 liters (4.5 US qts, 3.8 Imp. qts)
Drain and refill without oil filter change	4.1 liters (4.3 US qts, 3.6 Imp. qts)
Dry fill	5.0 liters (5.3 US qts, 4.4 Imp. qts)

Install the oil filler cap.

Install the engine cover with the 2 nuts.

Torque:

7.0 N*m{71 kgf*cm, 62 in.*lbf}