Timing Chain: Installation

1. After setting the crankshaft at ATDC40-140 °, set cams of intake and exhaust timing sprockets at ATDC 20 ° and then reset the crankshaft at ATDC 20 °
2. Install the chain vibration damper with the 2 bolts.

   Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) 

NOTE: To prevent the exhaust camshaft from spring back turn it using a wrench and set it at the mark on a chain.
Fig 1: Aligning Timing Chain Match Marks
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Align the match marks of timing chain mark plate (Yellow), camshaft timing sprocket, camshaft timing gear and crankshaft timing sprocket to install the timing chain as shown in the illustration.
4. Install the chain tensioner slipper.

1. While rotating the lock plate of the tensioner up-ward, push in the plunger of the tensioner as shown in the illustration.
2. While rotating the lock plate of the tensioner down-ward, insert a bar of 2.5 mm (0.098 in.) into the holes in the lock plate.
3. Install the chain tensioner with the 2 bolts.

   Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) 

4. Remove the bar from the chain tensioner.
   Fig 2: Removing Bar From Chain Tensioner

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Check that the tension between the intake and exhaust camshaft timing sprocket.

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.
   • Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
   • Thoroughly clean all components to remove all the loose material.
   • Using a non-residue solvent, clean both sealing surfaces.
NOTE: Avoid applying an excessive amount to the surface.
Fig 3: Applying Seal Packing To Timing Chain Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply seal packing to the timing chain cover as shown in Fig 3.

   Seal packing: 

   Part No. 08826 - 00100 or equivalent 

   • Install a nozzle that has been cut to a 4 - 5 mm (0.16 - 0.20 in.) opening.
   • FIPG shall be accumulated in the groove for FIPG to a depth of 2.5 mm (0.10 in.) or more.
   • Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
   • Immediately remove nozzle from the tube and reinstall cap.
NOTE: Avoid applying an excessive amount to the surface.
• Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
• Immediately remove nozzle from the tube and reinstall cap.
Fig 4: Locating Seal Packing Areas
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply seal packing to 4 locations as shown in the illustration.

   Seal packing: 

   Part No. 08826 - 00080 or equivalent 

   • Install a nozzle that has been cut to a 4 - 5 mm (0.16 - 0.20 in.) opening.
4. Install 2 new O-rings to the cylinder block and oil pan No. 1.
NOTE:
• Pay attention not to wrap the chain and slipper over the chain cover seal line.
• After installing the chain cover, must install the mounting bracket and water pump within 15 minutes.
5. Install the timing chain cover, new O-ring and water pump with the 16 bolts and 3 nuts. Uniformly tighten the bolts and nut in several passes.

   Torque: 

   Bolt A 11 N.m (113 kgf.cm, 8 ft.lbf) 

   Bolt B 24 N.m (245 kgf.cm, 18 ft.lbf) 

   Bolt C 11 N.m (113 kgf.cm, 8 ft.lbf) 

   Bolt D 24 N.m (245 kgf.cm, 18 ft.lbf) 

   Bolt E 11 N.m (113 kgf.cm, 8 ft.lbf) 

   Nut F 24 N.m (245 kgf.cm, 18 ft.lbf) 

   Nut G 11 N.m (113 kgf.cm, 8 ft.lbf) 

Fig 5: Identifying Timing Chain Cover Fastener Locations

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Do not apply seal packing to 2 or 3 threads of the bolt end.
1. Apply seal packing to threads of the mounting bolt.

   Seal packing: 

   Part No. 08826 - 00080 or equivalent 

2. Install the mounting bracket with the 4 bolts.
   Fig 6: Installing Mounting Bracket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 55 N.m (561 kgf.cm, 41 ft.lbf) 

Torque: 

Bolt A 7.5 N.m (76 kgf.cm, 66 in.lbf) 

Bolt B 11 N.m (113 kgf.cm, 8 ft.lbf) 

Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf) 

1. Clean the crankshaft pulley inside.
2. Install the pin to the crankshaft.
3. Align the hole in the crank pulley with the pin position and install the crank pulley.
4. Using SST, install the pulley bolt.
   Fig 7: Installing Pulley Bolt Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   SST 09213-70010, 09330-00021

   Torque: 128 N.m (1,300 kgf.cm, 94 ft.lbf) 

1. Remove any old packing (FIPG) material.
NOTE: Part must be assembled within 3 minutes of application. Otherwise the material must be remove and reapplied.
Fig 8: Applying Seal Packing To 2 Locations
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply seal packing to 2 locations as shown in Fig 8.

   Seal packing: 

   Part No. 08826 - 00080 or equivalent 

3. Install the gasket to the cylinder head cover.
4. Install the cylinder head cover and cable bracket with the 7 bolts, 2 seal washers and 2 nuts.

   Uniformly tighten the bolts and nuts, in several passes, in the sequence shown.

   Fig 9: Installing Cylinder Head Cover And Cable Bracket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 10 N.m (100 kgf.cm, 7 ft.lbf) 

5. Connect the 2 PCV hoses to the cylinder head cover.

Install the RH engine mounting insulator with the 5 bolts and 2 nuts.

Fig 12: Connecting Connectors

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1. Connect the Camshaft timing oil control valve connector.
2. Connect the water temperature sensor connector.
3. Connect the camshaft position sensor connector.
4. Connect the 2 VSV connectors.
5. Connect the 4 injector connectors.
6. Connect the 4 ignition connectors.

Fig 13: Installing Air Cleaner Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the air cleaner assembly with the 2 bolts.
2. Tighten the 2 hose clamps.
3. Connect the EVAP hose to the air cleaner case.
4. Connect the MAF meter connector.

Check for abnormal noises, shock slippage, correct shift points and smooth operation.