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Timing Belt: Installation

WARNING: This page is about a different car, the 2007 Lexus SC 430. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL NO. 2 TIMING BELT IDLER SUB-ASSEMBLY (See  REASSEMBLY   ) 
  2. INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY (See  REASSEMBLY   ) 
  3. INSTALL TIMING BELT 
    1. Check the No. 1 and No. 2 belt idler.
      1. Visually check the seal portion of the idler pulley for oil leakage.

        If leakage is found, replace the idler.

      2. Check that the idler turns smoothly.

        If necessary, replace the idler.

    2. Check the water pump.
      1. Visually check the air hole and water hole for coolant leakage.

        If leakage is found, replace the water pump and belt.

      2. Turn the pulley, and check that the water pump bearing moves smoothly and quietly.

        If necessary, replace the water pump.

    3. Remove any oil or water on the crankshaft, oil pump pulley, water pump pulley, No. 1 idler and No. 2 idler. Keep them clean.
      Fig 1: Identifying Air Hole And Drain Hole
      G05288717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Only wipe the pulleys. Do not use any cleaning agents on the pulleys.
    4. Set the No. 1 cylinder to TDC/compression.
      Fig 2: Identifying Timing Marks
      G05288718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Turn the hexagon wrench head portion of the camshaft to align the timing marks of the camshaft timing pulleys and timing belt plates.

        HINT:

        Turn the camshaft timing pulleys slightly clockwise to make installation of the timing belt easier.

        Camshaft timing pulley of LH bank: 1/2 of a tooth

        Camshaft timing pulley of RH bank: 1 tooth

        Fig 3: Identifying Camshaft Timing Pulley Of RH And LH Bank
        G05288719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Using the crankshaft pulley bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body.
        Fig 4: Aligning Timing Marks Of Crankshaft Timing Pulley And Oil Pump Body
        G05288720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Remove any oil or water on each pulley. Keep them clean.
        NOTE: Only wipe the pulleys. Do not use any cleaning agents on the pulleys.
      4. Face the front mark (arrow) on the belt forward.
      5. Connect the belt to the crankshaft timing pulley. Align the installation mark on the belt with the timing mark of the crankshaft timing pulley.
      6. Connect the belt to the No. 2 idler.
      7. Connect the belt to the camshaft timing pulley (LH bank).
        Fig 5: Identifying Installation Mark On Belt
        G05288721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Align the installation mark on the belt with the timing mark of the camshaft timing pulley.

      8. Connect the belt to the water pump pulley.
      9. Connect the belt to the camshaft timing pulley (RH bank).

        Align the installation mark on the belt with the timing mark of the camshaft timing pulley.

      10. Connect the timing belt to the No. 1 idler.
    5. Set the belt tensioner.
      1. Using a press, slowly press in the push rod using 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) of pressure.
      2. Align the holes of the push rod and housing. Pass a 1.27 mm 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 6: Setting Belt Tensioner
        G05288722Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the belt tensioner.
      1. Temporarily install the belt tensioner with the 2 bolts.
      2. Alternately tighten the 2 bolts.

        Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) 

      3. Using pliers, remove the 1.27 mm hexagon wrench from the belt tensioner.
        Fig 7: Installing Belt Tensioner With 2 Bolts
        G05288723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Check the valve timing.
      1. Using the crankshaft pulley bolt, slowly turn the crankshaft timing pulley 2 revolutions from TDC to TDC.
        NOTE: Always turn the crankshaft pulley clockwise.
        Fig 8: Turning Crankshaft Pulley
        G05288724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Check that each pulley aligns with the timing marks as shown in the illustration.

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

      3. Remove the crankshaft pulley bolt.
        Fig 9: Aligning Timing Marks Of Camshaft Timing Pulleys And Timing Belt Plates
        G05288725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL CRANKSHAFT POSITION SENSOR PLATE 
    1. Install the crankshaft position sensor plate as shown in the illustration.
      NOTE: Be careful of the installation direction.
      Fig 10: Identifying Crankshaft Position Sensor Plate
      G05288726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL TIMING GEAR COVER SPACER 
    1. Install the gasket to the cover spacer.
    2. Install the cover spacer.
      Fig 11: Locating Timing Gear Cover Spacer
      G05288727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL NO. 1 TIMING BELT COVER 
    1. Install the timing belt cover with the 4 bolts.

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

      Fig 12: Locating Timing Belt Cover Bolts
      G05288728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL CRANKSHAFT PULLEY 
    1. Align the damper set key with the key groove of the pulley.
    2. Using SST and a hammer, tap on the pulley.

      SST 09223-46011 

      Fig 13: Taping On Pulley
      G05288729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, install the pulley bolt.

      SST 09213-70011, 09330-00021 

      Torque: 245 N*m (2,498 kgf*cm, 181 ft.*lbf) 

      Fig 14: Installing Pulley Bolt
      G05288730Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL IDLER PULLEY ASSEMBLY 
    1. Install the idler with the 2 bolts and 2 nuts.

      Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) for 12 mm head 

      32 N*m (326 kgf*cm, 24 ft.*lbf) for 14 mm head 

      Bolt length: 

      106 mm (4.17 in.) for 12 mm head (A) 

      114 mm (4.49 in.) for 14 mm head (B) 

      Fig 15: Locating Idler Pulley Assembly Bolts And Nuts
      G05288731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Install the belt tensioner with the bolt and 2 nuts.

      Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) 

      HINT:

      Use bolts that are 106 mm (4.17 in.) in length.

      Fig 16: Locating V-Ribbed Belt Tensioner Assembly Bolt And Nuts
      G05288732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL NO. 2 TIMING BELT COVER SUB-ASSEMBLY 
    1. Set the No. 2 cover by matching the claws and pin with each part.
    2. Install the timing belt cover with the 2 bolts.

      Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) 

      HINT:

      Use bolts that are 106 mm (4.17 in.) in length.

      Fig 17: Locating Timing Belt Cover Bolts
      G05288733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY 
    1. Install the idler pulley and cover plate with the bolt.

      Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) 

      Fig 18: Locating Pulley Bolt
      G05288734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL NO. 3 TIMING BELT COVER SUB-ASSEMBLY LH 
    1. Install the gasket to the cover.
    2. Run the camshaft position sensor wire through the cover hole.
    3. Install the cover with the 4 bolts.

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

    4. Install the wire grommet to the cover.
    5. Install the sensor connector to the sensor holder.
    6. Connect the sensor connector.
    7. Install the sensor wire to the wire clamp on the cover.
      Fig 19: Locating Timing Belt Cover Bolts And Connector
      G05288735Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install the engine wire to the 2 wire clamps on the cover.
    9. Connect the 2 water bypass hoses as shown in the illustration.
    10. Install the No. 3 water bypass pipe to the cover with the cap nut.

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

      Fig 20: Identifying Water Bypass Hoses
      G05288736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL NO. 3 TIMING BELT COVER SUB-ASSEMBLY RH 
    1. Install the gasket to the cover.
      Fig 21: Locating Timing Belt Cover Bolts
      G05288737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the cover with the cap nut and 3 bolts.

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

    3. Install the 2 PS air hoses to the clamp on the cover.
  14. CONNECT COOLER COMPRESSOR ASSEMBLY 
    1. Set the cooler compressor to the engine. Then install the stay, wire bracket, 3 bolts and nut to connect the cooler compressor.

      Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) for bolts 

      29 N*m (296 kgf*cm, 21 ft.*lbf) for nuts 

  15. INSTALL GENERATOR ASSEMBLY (See  INSTALLATION  ) 
  16. INSTALL VANE PUMP ASSEMBLY (See  INSTALLATION   ) 
  17. INSTALL FAN AND GENERATOR V BELT (See  INSTALLATION   ) 
  18. INSTALL RADIATOR ASSEMBLY (See  INSTALLATION  ) 
  19. CONNECT NO. 1 OIL COOLER OUTLET TUBE (See  INSTALLATION  ) 
  20. CONNECT NO. 1 OIL COOLER INLET TUBE (See  INSTALLATION  ) 
  21. CONNECT NO. 2 RADIATOR HOSE (See  INSTALLATION  ) 
  22. CONNECT NO. 1 RADIATOR HOSE (See  INSTALLATION  ) 
  23. INSTALL AIR CLEANER ASSEMBLY (See  INSTALLATION   ) 
  24. INSTALL INTAKE AIR CONNECTOR PIPE (See  INSTALLATION   ) 
  25. INSTALL NO. 1 AIR CLEANER INLET (See  INSTALLATION   ) 
  26. INSTALL V-BANK COVER (See  INSTALLATION   ) 
  27. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  28. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION ).
      NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
  29. ADD ENGINE COOLANT (See  COOLANT  ) 
  30. CHECK FOR ENGINE COOLANT LEAKS (See  COOLING SYSTEM  ) 
  31. INSTALL ENGINE UNDER COVER 
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