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Timing Belt: Installation

  1. INSTALL CRANKSHAFT TIMING PULLEY 
    1. Align the pulley set key with the key groove of the pulley.
    2. Slide on the timing pulley facing the flange side inward.
      NOTE: Do not scratch the sensor part of the crankshaft timing pulley.
      Fig 1: Sliding On Timing Pulley Facing Flange Side Inward
      G02948756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the timing belt plate with the bolt.
      1. Torque: 8.0 N.m (80 kgf.cm, 71 in.lbf) 
      Fig 2: Installing Timing Belt Plate With Bolt
      G02948757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL IDLER PULLEY 
    1. Apply adhesive to 2 or 3 threads of the pivot bolt.

      Adhesive: 

      Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

      2. Fig 3: Applying Adhesive To Threads Of Pivot Bolt And Installing Idler Pulley
      G02948758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a 10 mm hexagon wrench, install the plate washer and pulley with the pivot bolt.
      1. Torque: 35 N.m (350 kgf.cm, 26 ft.lbf) 
    3. Check that the pulley bracket moves smoothly.
  3. TEMPORARILY INSTALL TIMING BELT 
    NOTE: The engine should be cold.
    1. Use the crankshaft pulley bolt to turn the crankshaft, and align the dot mark on the crankshaft timing pulley and the timing mark on the oil pump body.
      2. Fig 4: Aligning Dot Mark On Crankshaft Timing Pulley And Timing Mark On Oil Pump Body
      G02948759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove any oil or water on the crankshaft timing pulley and idler pulley, and keep them clean.
    3. Install the timing belt on the crankshaft timing pulley and idler pulley.

    HINT:

    When re-using timing belt:

    Align the matchmarks of the crankshaft timing pulley and timing belt, and install the belt with the arrow pointing in the direction of engine revolution.

    Fig 5: Aligning Matchmarks Of Crankshaft Timing Pulley And Timing Belt
    G02948760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL TIMING BELT GUIDE 

    Install the guide, facing the cup side outward.

    Fig 6: Installing Timing Belt Guide
    G02948761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL NO. 1 TIMING BELT COVER 
    1. Install the gasket to the timing belt cover.
    2. Install the timing belt cover with the 5 bolts.
      1. Torque: 8.0 N.m (80 kgf.cm, 71 in.lbf) 
  6. INSTALL CRANKSHAFT PULLEY 
    1. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
    2. Check that the sub timing mark (60° mark BTDC) of the crankshaft pulley is aligned with the timing mark "0" of the No.1 timing belt cover.

      HINT:

      At this time, the crankshaft pulley set key groove and the timing mark (TDC mark) of the crankshaft pulley are as shown the illustration.

    3. Temporarily install the pulley bolt.
    Fig 7: Installing Crankshaft Pulley
    G02948762Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL VVT-i (INTAKE CAMSHAFT TIMING) PULLEY 
    1. Align the camshaft knock pin with the VVT-i pulley, and push the VVT-i pulley by hand until you feel it touch the bottom.
      Fig 8: Aligning Camshaft Knock Pin With VVT-i Pulley And Pushing VVT-i Pulley By Hand Until You Feel It Touch Bottom
      G02948763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check that the outer circumference of the VVT-i pulley easily rotates through 30°.
      Fig 9: Checking That Outer Circumference Of VVT-i Pulley Easily Rotates Through 30°
      G02948764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Holding the hexagon portion of the camshaft with a wrench.
    4. Using a 10 mm hexagon wrench, and the set bolt.
      1. Torque: 81 N.m (810 kgf.cm, 60 ft.lbf) 
    5. Using a 14 mm hexagon wrench, install the straight screw plug with the seal washer to the set bolt.
      1. Torque: 15 N.m (150 kgf.cm, 11 ft.lbf) 
      Fig 10: Installing Straight Screw Plug With Seal Washer To Set Bolt
      G02948765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Align the dot mark on the camshaft timing pulley with the timing mark of the No. 4 timing belt cover.
    7. Remove the wrench.
  8. CONNECT NO.1 OIL PIPE 
    1. Install the union bolt to the oil control valve filter.
      NOTE: In case of touching the filter, avoid holding the mesh part and holding the frame part.
      Fig 11: Identifying Union Bolt
      G02948766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the oil pipe with 2 new gasket and the union bolt to the No.3 camshaft bearing cap.
      1. Torque: 55 N.m (550 kgf.cm, 41 ft.lbf) 
  9. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE (See  INSPECTION  ) 
  10. INSTALL NO.1 CYLINDER HEAD COVER 
    1. Install the cylinder head and gasket with the 6 bolts.
      1. Torque: 8.5 N.m (85 kgf.cm, 75 in.lbf) 
    2. Using a torx socket (E5), install the 2 stud bolts.
      1. Torque: 8.5 N.m (85 kgf.cm, 75 in.lbf) 
        2. Fig 12: Using Torx Socket (E5) To Install Stud Bolts
        G02948767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 2 nuts to the 2 stud bolts.
      1. Torque: 8.5 N.m (85 kgf.cm, 75 in.lbf) 
    4. Install the high-tension cords and clamps with the 2 bolts.
      1. Torque: 8.0 N.m (80 kgf.cm, 71 in.lbf) 
    5. Using a 5 mm hexagon wrench, install the engine wire protector with the bolt and nut.
      6. Fig 13: Using 5 mm Hexagon Wrench To Install Engine Wire Protector With Bolt And Nut
      G02948768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL THROTTLE BODY AND INTAKE AIR CONNECTOR ASSEMBLY (See  VALVE CLEARANCE  ) 
  12. INSTALL ENGINE COVER 

    Install the engine cover with the 4 nuts.

  13. INSTALL EXHAUST CAMSHAFT TIMING PULLEY 
    1. Align the camshaft knock pin with the groove on the pulley, and slide on the timing pulley.
    2. Slide the timing pulley on the camshaft, facing the front mark forward.
    3. Using SST, install the pulley bolt.

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

      1. Torque: 81 N.m (810 kgf.cm, 60 ft.lbf) 
      Fig 14: Using SST To Install Pulley Bolt
      G02948769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, align the dot mark on the camshaft timing pulley with the timing mark of the No. 4 timing belt cover.

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

    Fig 15: Using SST To Align Dot Mark On Camshaft Timing Pulley With Timing Mark Of No. 4 Timing Belt Cover
    G02948770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. CONNECT TIMING BELT TO CAMSHAFT TIMING PULLEYS 

    HINT:

    When re-using timing belt:

    • Check that the matchmark on the timing belt matches the end of the No. 1 timing belt cover.

      If the matchmark does not align, shift the meshing of the timing belt and crankshaft timing pulley until they align.

    • Align the matchmarks of the timing belt and camshaft timing pulleys.
      • Fig 16: Aligning Matchmarks Of Timing Belt And Camshaft Timing Pulleys
      G02948771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove any oil or water on the camshaft timing pulley, and keep it clean.
    2. Install the timing belt, checking the tension between the crankshaft timing pulley and intake camshaft timing pulley.
    Fig 17: Installing Timing Belt And Checking Tension Between Crankshaft Timing Pulley And Intake Camshaft Timing Pulley
    G02948772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. SET TIMING BELT TENSIONER 
    1. Using a press, slowly press in the push rod using 981-9,807 N (100-1,000 kgf, 220-2,205 lbf) of force.
    2. Align the holes of the push rod and housing, pass a 1.5 mm hexagon wrench through the holes to keep the push rod retracted.
      3. Fig 18: Passing Hexagon Wrench Through Holes For Keeping Push Rod Retracted
      G02948773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Release the press.
    4. Install the dust boot onto the tensioner.
      5. Fig 19: Installing Dust Boot Onto Tensioner
      G02948774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL TIMING BELT TENSIONER 
    1. Temporarily install the tensioner with the 2 bolts.
      2. Fig 20: Installing Timing Belt Tensioner
      G02948775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Alternately tighten the 2 bolts.
      1. Torque: 27 N.m (270 kgf.cm, 20 ft.lbf) 
    3. Remove the 1.5 mm hexagon wrench from the tensioner with pliers.
      4. Fig 21: Removing Hexagon Wrench From Tensioner With Pliers
      G02948776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. CHECK VALVE TIMING 
    1. Slowly turn the crankshaft pulley 2 revolutions from TDC to TDC.
      NOTE: Always turn the crankshaft clockwise.
      Fig 22: Turning Crankshaft Pulley Revolutions From TDC To TDC
      G02948777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check that each pulley aligns with the timing marks as shown in the illustration.

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

    Fig 23: Aligning Each Pulley With Timing Marks
    G02948778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. TIGHTEN CRANKSHAFT PULLEY BOLT 

    Using SST, install the pulley bolt.

    SST 09213-70011, 09330-00021

    Torque: 330 N.m (3,300 kgf.cm, 243 ft.lbf)

    Fig 24: Using SST To Install Pulley Bolt
    G02948779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL DRIVE BELT TENSIONER 

    Install the tensioner with the 3 bolts.

    1. Torque: 21 N.m (210 kgf.cm, 15 ft.lbf) 
    NOTE: Be careful not to drop the bolts inside the timing belt cover.
  20. INSTALL NO.2 TIMING BELT COVER 
    1. Install the gasket on the timing belt cover.
    2. Using a 5 mm hexagon wrench, install the timing belt cover with the 3 bolts.
      1. Torque: 8.0 N.m (80 kgf.cm, 71 in.lbf) 
  21. INSTALL NO.3 TIMING BELT COVER 
    1. Install the gasket on the timing belt cover.
    2. Using a 5 mm hexagon wrench, install the timing belt cover with the 4 bolts.
      1. Torque: 8.0 N.m (80 kgf.cm, 71 in.lbf) 
    3. Install the oil filler cap.
  22. INSTALL PS PUMP AND FRONT BRACKET 
    1. Temporarily install the vane pump to the bracket.
    2. Install the plate washer and front bracket with the 3 bolts.
      1. Torque: 

        58 N.m (590 kgf.cm, 43 ft.lbf) for bolt A 

        52 N.m (530 kgf.cm, 38 ft.lbf) for bolt B 

      Fig 25: Installing Plate Washer And Front Bracket With Bolts
      G02948780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL DRIVE BELT (See  CHARGING SYSTEM  ) 
  24. M/T: 

    INSTALL DRIVE BELT TENSIONER ABSORBER 

    Install the absorber with the 2 nuts.

    1. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 
  25. INSTALL RADIATOR ASSEMBLY (See  INSTALLATION  ) 
  26. FILL ENGINE WITH COOLANT 
  27. START ENGINE CHECK FOR LEAKS 
  28. INSTALL ENGINE UNDER COVER 
  29. ROAD TEST 

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

  30. RECHECK ENGINE COOLANT LEVEL 
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