Timing Belt: Installation

1. Align the timing pulley set key with the key groove of the pulley.
2. Using SST and a hammer, tap in the timing pulley, facing the flange side inward.
   1. SST 09223-46011

Fig 1: Tapping Timing Pulley Using SST & Hammer

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply adhesive 2 or 3 threads from the end of the pivot bolt.
   1. Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
2. Using a 10 mm hexagon wrench, install the plate washer and the No. 1 idler pulley with the pivot bolt.
   1. Torque: 34.5 N.m (350 kgf.cm, 25 ft.lbf) 
Fig 2: Installing Plate Washer Using Hexagonal Wrench
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the No. 2 idler pulley with the bolt.
   1. Torque: 34.5 N.m (350 kgf.cm, 25 ft.lbf) 
4. Check that the No. 1 and No. 2 idler pulley moves smoothly.

1. Remove any oil or water on and clean the crankshaft pulley, the oil pump pulley, the water pump pulley, the No. 1 idler pulley and the No. 2 idler pulley.
   NOTE: Only wipe the pulleys; do not use any cleansing agent. 
2. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
3. Install the timing belt on the crankshaft timing pulley, the No. 1 idler pulley and the No. 2 idler pulley.

Fig 3: Installing Timing Belt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the gasket to the cover spacer.
2. Install the cover spacer.

Install the belt guide, facing the cup side outward.

Install the timing belt cover with the 4 bolts.

1. Align the pulley set key with the key groove of the crankshaft pulley.
2. Using SST and a hammer, tap in the crankshaft pulley.
   1. SST 09223-46011
Fig 5: Tapping In Crankshaft Pulley Using SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Torque: 16 N.m (160 kgf.cm, 12 ft.lbf) 

HINT:

Use a bolt of 106 mm (4.18 in.) in length.

Check that the timing mark of the crankshaft pulley is aligned with timing mark "0" of the No. 1 timing belt cover.

Fig 6: Locating Timing Mark

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Align the camshaft knock pin with the knock pin grove of the timing pulley, and side on the timing pulley.
2. Using SST, install the pulley bolt.
   1. SST 09960-10010 (09962-01000, 09963-01000)
   2. Torque: 108 N.m (1,100 kgf.cm, 80 ft.lbf) 

Fig 7: Installing RH, LH Camshaft Timing Pulleys

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove any oil or water on the LH camshaft timing pulley and clean it up.
   NOTE: Only wipe the pulleys; do not use any cleansing agent. 
2. Turn the LH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley, and hang the timing belt on the LH camshaft timing pulley.
Fig 8: Turning LH Camshaft Timing Pulley
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Turn the LH camshaft timing pulley counterclockwise until there is tension between the crankshaft timing pulley and the LH camshaft timing pulley.

Fig 9: Turning LH Camshaft Timing Pulley Counterclockwise

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove any oil or water on the RH camshaft timing pulley and water pump pulley, and clean them up.
   NOTE: Only wipe the pulleys; do not use any cleansing agent. 
2. Turn the RH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley, and hang the timing belt on the RH camshaft timing pulley.

1. Using a press, slowly press in the push rod using 981-9,807 N (100 - 1,000 kgf, 220 - 2,205 lbf) of pressure.
2. Align the holes of the push rod and the housing, pass a 1.27 mm (0.050 in.) 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.

Fig 11: Pressing In Push Rod Using Press

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Temporarily install the belt tensioner with the 2 bolts.
2. Alternately tighten the 2 bolts.
   1. Torque: 26 N.m (270 kgf.cm, 19 ft.lbf) 
3. Using pliers, remove the 1.27 mm (0.050 in.) hexagon wrench from the belt tensioner.

Fig 12: Removing Hexagon Wrench From Belt Tensioner

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Temporarily install the crankshaft pulley bolt.
2. Slowly turn the crankshaft pulley 2 revolutions from TDC to TDC.
   NOTE: Always turn the crankshaft pulley clockwise. 
   Fig 13: Turning Crankshaft Pulley

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check that each pulley aligns with the timing marks as shown in Fig 14 .

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

   Fig 14: Identifying Timing Marks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using SST, install the pulley bolt.

1. SST 09213-70011 (90105-70020), 09330-00021
2. Torque: 245 N.m (2,500 kgf.cm, 181 ft.lbf) 

Fig 15: Installing Pulley Bolt Using SST

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the fan bracket with the 2 bolts and the 2 nuts.

Fig 16: Installing Fan Bracket, Bolts & Nuts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 

1. 12 mm head 
   1. 16 N.m (160 kgf.cm, 12 ft.lbf) 
2. 14 mm head 
   1. 32 N.m (330 kgf.cm, 24 ft.lbf) 

HINT:

Bolt Length:

1. 106 mm (4.17 in.) for 12 mm head (A)
2. 114 mm (4.49 in.) for 14 mm head (B)

Install the No. 2 timing belt cover with the 2 bolts.

Fig 17: Installing Timing Belt Cover & Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Torque: 16 N.m (160 kgf.cm, 12 ft.lbf) 

1. Fit the RH No. 3 timing belt cover, matching it with the fan bracket.
2. Install the RH No. 3 timing belt cover with the 3 bolts and nut.
   1. Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 

Fig 18: Installing RH No. 3 Timing Belt Cover

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the oil cooler pipe and the bolt.
2. Run the camshaft position sensor wire through the LH No. 3 timing belt cover hole.
3. Fit the LH No. 3 timing belt cover, matching it with the fan bracket.
4. Install the LH No. 3 timing belt cover with the 4 bolts and the nut.
   1. Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 
5. Install the wire grommet to the LH No. 3 timing belt cover.
6. Install the sensor connector to the connector bracket.
7. Connect the sensor connector.
8. Install the sensor wire to the wire clamp on the LH No. 3 timing belt cover.
9. Install the engine wire to the 2 wire clamps on the LH No. 3 timing belt cover.

Fig 19: Installing LH No. 3 Timing Belt Cover

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 

1. Temporarily install the fan pulley, the fan, the fluid coupling assembly with the 4 nuts.
2. Install the generator drive belt. (See GENERATOR )
3. Tighten the 4 nuts holding the fluid coupling to the fan bracket.
   1. Torque: 21 N.m (215 kgf.cm, 16 ft.lbf) 

Fig 20: Installing Fan Pulley, Fan, Fluid Coupling, Drive Belt & Nuts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002