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Timing Chain: Installation

  1. INSTALL CAMSHAFT TIMING SPROCKET AND VVT TIMING SPROCKET 
    1. Install the camshaft timing sprocket.
      1. Face the timing mark of the sprocket outward.
      2. Align the camshaft knock pin with the knock pin groove on the sprocket side with the timing mark, and slide on the timing sprocket.
        Fig 1: Aligning Camshaft Timing Sprocket Timing Mark
        G02853996Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Temporarily install the timing sprocket set bolt.
        4. Fig 2: Installing Timing Sprocket Set Bolt
        G02853997Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Hold the hexagon wrench head portion of the exhaust camshaft with a wrench, and tighten the bolt.
      1. Torque: 54 N.m (550 kgf.cm, 40 ft.lbf) 
    2. Install the VVT timing sprocket.
      Fig 3: Locating VVT Timing Sprocket Timing Mark
      G02853998Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Holding the timing sprocket in the position where the timing sprocket pin groove is slightly to right of the camshaft pin looking from the front side, install the timing sprocket to the camshaft, lightly pressing and turning it counterclockwise. Check that there is virtually no clearance between the timing sprocket and camshaft flange.
        NOTE: Be careful not to turn the timing sprocket clockwise when installing it.
      2. Temporarily install the timing sprocket set bolt.
      3. Hold the hexagon wrench head portion of the intake camshaft with a wrench.
      4. Take care to install the timing sprocket with the bolt
        1. Torque: 54 N.m (550 kgf.cm, 40 ft.lbf) 
      5. Check that the valve timing controller turns clockwise and that it is locked securely when the lock pin in hole is at the locking point.
    3. SET NO. 1 CYLINDER TO TDC/COMPRESSION 
      1. Turn the hexagonal wrench head portion of the camshafts, and align the timing marks of the camshaft timing sprocket and VVT timing sprocket with the timing marks of No 1 and No. 2 bearing caps as shown in the illustration.
        2. Fig 4: Aligning Camshaft Timing Sprocket & VVT Timing Sprocket Timing Marks
        G02853999Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward.
        Fig 5: Turning Crankshaft & Setting Set Key On Crankshaft
        G02854000Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. INSTALL CHAIN VIBRATION DAMPER 

        Install the damper with the 2 bolts.

        Fig 6: Locating Chain Vibration Damper Bolts
        G02854001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        1. Torque: 9 N.m (90 kgf.cm, 80 in..lbf) 
      4. INSTALL CRANKSHAFT TIMING SPROCKET 

        Align the sprocket set key with the key groove of the sprocket, slide on the sprocket.

      5. INSTALL TIMING CHAIN 
        Fig 7: Installing Timing Chain
        G02854002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        1. Install the timing chain on the crankshaft timing sprocket with the blue or orange mark link aligned with the timing mark on the crankshaft timing sprocket.
          Fig 8: Aligning Crankshaft Timing Sprocket With Gold Or Yellow Mark Link
          G02854003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        2. Install the timing chain on the camshaft timing sprocket and VVT timing sprocket with the gold or yellow mark links aligned with the timing marks on the camshaft timing sprocket and VVT timing sprocket.
          Fig 9: Aligning Crankshaft & VVT Timing Sprocket With Gold Or Yellow Mark Links
          G02854004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      6. INSTALL TIMING CHAIN GUIDE 

        Install the timing chain guide with the bolt.

        1. Torque: 9 N.m (90 kgf.cm, 80 in..lbf) 
      7. INSTALL CHAIN TENSIONER SLIPPER 
        1. Install the slipper with the bolt.
          Fig 10: Installing Chain Tensioner Slipper
          G02854005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
          1. Torque: 19 N.m (195 kgf.cm, 14 ft.lbf) 
        2. Check that the slipper is hold on the cylinder block stopper.
      8. INSTALL CRANK ANGLE SENSOR PLATE 
        Fig 11: Installing Rank Angle Sensor Plate
        G02854006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Install the plate with the F mark facing forward.

      9. INSTALL TIMING CHAIN COVER 
        1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover and cylinder head/block/crank case.
          • Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
            Fig 12: Identifying Old Packing (FIPG) Material
            G02854007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
          • Thoroughly clean all components to remove all the loose material.
          • Using a non-residue solvent, clean both sealing surfaces.
        2. Apply seal packing to the timing chain cover as shown in the illustration.

          Seal packing: Part No. 08826-00080 or equivalent 

          • Install a nozzle that has been cut to a 3 - 4 mm (0.12 - 0.16 in.) opening.
            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.
        3. Apply seal packing to 2 locations as shown in the illustration.
          Fig 13: Locating Seal Packing Applying Point
          G02854008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

          Seal packing: Part No. 08826-00080 or equivalent 

          • Install a nozzle that has been cut to a 2 mm (0.08 in.) opening.
            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.
        4. Install the timing chain cover with the 14 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.
          Fig 14: Installing Timing Chain Cover Bolts & Nuts
          G02854009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
          1. Torque: 

          9 N.m (90 kgf.cm, 80 in..lbf) for bolt A 

          21 N.m (220 kgf.cm, 15 ft.lbf) for bolt B 

          43 N.m (440 kgf.cm, 32 ft.lbf) for bolt C 

          43 N.m (440 kgf.cm, 32 ft.lbf) for bolt D 

          9 N.m (90 kgf.cm, 80 ft.lbf) for nuts 

          NOTE:
          BOLT LENGTH SPECIFICATIONS

          Bolt A 30 mm (1.18 in.) Length For 10 mm Head
          Bolt B 30 mm (1.18 in.) Length For 12 mm Head
          Bolt C 40 mm (1.57 in.) Length For 14 mm Head
          Bolt D 65 mm (2.56 in.) Length For 14 mm Head
        5. Using a Torx socket wrench (E10), install the stud bolt for the drive belt tensioner.
          1. Torque: 9.5 N.m (90 kgf.cm, 84 in..lbf) 
          Fig 15: Installing Stud Bolt Using A Torx Socket Wrench
          G02854010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        6. INSTALL DRIVE BELT TENSIONER 
          Fig 16: Installing Drive Belt Tensioner Bolt & Nut
          G02854011Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

          Install the drive belt tensioner with the bolt and nut.

          1. Torque: 59.5 N.m (610 kgf.cm, 44 ft.lbf) 
          NOTE: As the drive belt tensioner should be torqued together with the timing chain cover, so be sure install it with in 15 minutes after the timing chain cover is installed.
        7. INSTALL CRANKSHAFT POSITION SENSOR (See  REMOVAL & INSTALLATION (RAV4)  ) 
        8. INSTALL OIL PAN (See  INSTALLATION  ) 
        9. INSTALL CRANKSHAFT PULLEY 
          1. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
          2. Using SST, install the pulley bolt.
            Fig 17: Installing Pulley Bolt Using SST
            G02854012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

            SST 09213-54015, 09330-00021

            1. Torque: 170 N.m (1,735 kgf.cm, 125 ft.lbf) 
        10. INSTALL CHAIN TENSIONER 
          1. Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out.
            Fig 18: Releasing Ratchet Pawl & Applying Hook To Pin
            G02854013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
          2. Place a new gasket on the timing chain cover with portion A facing as shown in the illustration.
            Fig 19: Identifying Gasket Facing On Timing Chain Cover
            G02854014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
          3. Push the chain tensioner into the timing chain cover, and install the 2 nuts.
            1. Torque: 9 N.m (90 kgf.cm, 80 in..lbf) 
            Fig 20: Installing Chain Tensioner & Nut
            G02854015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        11. SET CHAIN TENSION 
          1. Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook.
            Fig 21: Disconnecting Plunger Knock Pin From Hook
            G02854016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
          2. Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.
            Fig 22: Turning Crankshaft Clockwise
            G02854017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        12. CHECK VALVE TIMING 
          1. Turn the crankshaft pulley, and align its groove with timing mark 0 of the timing chain cover.
            Fig 23: Turning Crankshaft Pulley & Aligning Its Groove With Timing Chain Cover Timing Mark
            G02854018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
            NOTE: Always turn the crankshaft clockwise.
          2. Check that the timing marks of the camshaft timing sprocket and VVT timing sprocket are aligned with the timing marks of the No. 1 and No. 2 bearing caps as shown in the illustration.
            3. Fig 24: Identifying Camshaft Timing & VVT Timing Sprocket Timing Marks Aligned Position
            G02854019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

        13. INSTALL CYLINDER HEAD COVER 
          1. Remove any old packing (FIPG) material.
          2. Apply seal packing to 2 locations as shown in the illustration.

            Seal packing: Part No. 08826-00080 or equivalent 

            Fig 25: Locating Seal Packing Apply Points
            G02854020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
          3. Install the gasket to the cylinder head cover.

            If the gasket has damage, replace a new one.

            NOTE: Part must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
          4. Install the cylinder head cover with the 8 bolts and 2 nuts.
            1. Torque: 11 N.m (115 kgf.cm, 8 ft.lbf) 
          5. Connect the 2 PCV hoses to the cylinder head cover.
        14. INSTALL IGNITION COILS (See  REMOVAL & INSTALLATION (RAV4) 
        15. INSTALL VANE PUMP (See  INSTALLATION  ) 
        16. INSTALL GENERATOR (See  REMOVAL & INSTALLATION  ) 
        17. INSTALL RH ENGINE MOUNTING INSULATOR (See  REMOVAL  ) 
          Fig 26: Installing Cylinder Head Cover Bolts And Nuts
          G02854021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        18. INSTALL DRIVE BELT (See  REMOVAL & INSTALLATION  ) 
        19. INSTALL ABS ACTUATOR (See ) 
        20. INSTALL AIR CLEANER ASSEMBLY (See  INSTALLATION  ) 
        21. INSTALL ENGINE UNDER COVER 
        22. FILL WITH ENGINE OIL (See  REPLACEMENT  ) 
        23. START ENGINE AND CHECK FOR LEAK 
        24. RECHECK ENGINE OIL LEVEL 
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