Timing Chain: Installation

1. Align the camshaft knock pin with the knock pin groove on the sprocket side with the timing mark, and slide on the camshaft timing sprocket and VVT timing sprocket.
   Fig 1: Reinstalling Camshaft Sprockets

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2. Temporarily install the 2 timing sprocket bolts.
3. Hold the hexagon wrench head portion of the camshaft with a wrench, and tighten the timing sprocket bolt.
   Fig 2: Using Wrench To Hold Camshaft While Tightening Sprocket Bolts

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   Torque: 54 N.m (551 kgf.cm, 40 ft.lbf) 

1. Turn the hexagonal wrench head portion of the camshafts, and align the point marks of the camshaft timing sprockets.
   Fig 3: Aligning Camshaft Sprockets

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2. Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward.
   Fig 4: Aligning Camshaft Using Set Key

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Install the damper with the 2 bolts.

Fig 5: Installing Chain Vibration Damper

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Torque: 9 N.m (92 kgf.cm, 80 in. lbf) 

1. Install the timing chain on the crankshaft timing sprocket with the #1 mark link aligned with the timing mark on the crankshaft timing sprocket.
   Fig 6: Aligning Timing Chain With Crankshaft Sprocket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: If necessary, tap in the sprocket with SST and a hammer.

   SST 09223-22010

   Fig 7: Using SST To Tap In Crankshaft Sprocket

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2. Install the timing chain on the camshaft timing sprocket and VVT timing sprocket with the #53 and #67 mark links aligned with the timing marks on the camshaft timing sprocket and VVT timing sprocket.
   Fig 8: Aligning Timing Chain With Camshaft Sprockets

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check the tension between the VVT timing sprocket and crankshaft timing sprocket.

1. Install the slipper with the bolt.
   Fig 9: Installing Chain Tensioner Slipper

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   Torque: 18.5 N.m (189 kgf.cm, 14 ft.lbf) 

2. Check that the slipper is held on the cylinder head stopper.
   NOTE: Do not turn the crankshaft.

Install the plate with the F mark facing forward.

Fig 10: Installing Crank Angle Sensor Plate In Proper Direction

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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.
2. Apply seal packing to the timing chain cover as shown in the illustration.
   Fig 11: Locating Seal Packing Areas

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   Seal packing position:

   Fig 12: Identifying Seal Packing Positions

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   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.
     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.
   Fig 13: Identifying 2 Additional Seal Packing Locations

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   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.
     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, a new O-ring and the water pump with the 17 bolts and nut. Uniformly tighten the bolts and nut in several passes.
   Fig 14: Identifying Locations Of Different-Length Bolts

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   NOTE: Each bolt length in indicated in the illustration.

   Fig 15: Identifying Bolt Lengths

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   Torque: 

   1. 18.5 N.m (189 kgf.cm, 14 ft.lbf) for A 
   2. 13 N.m (133 kgf.cm, 10 ft.lbf) for B 
   3. 9 N.m (92 kgf.cm, 80 in.lbf) for C 
   4. 11 N.m (113 kgf.cm, 8 ft.lbf) for others 
   NOTE:

   • Pay attention not to wrap the chain and slipper over the chain cover seal line.
   • After installing the chain cover, install the mounting bracket and water pump within 15 minutes.

1. Apply seal packing to threads of the mounting bolt.

   Seal packing: Part No. 08826-00080 or equivalent 

   NOTE: Do not apply seal packing to 2 or 3 threads of the bolt end.
2. Install the engine mounting bracket with the 3 bolts.
   Fig 16: Installing Right Hand Engine Mounting Bracket

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   Torque: 47 N.m (479 kgf.cm, 35 ft.lbf) 

1. Install the drive belt tensioner with the bolt and nut.
   Fig 17: Installing Drive Belt Tensioner

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   Torque: 

   1. 69 N.m (704 kgf.cm, 51 ft.lbf) for bolt 
   2. 29 N.m (296 kgf.cm, 21 ft.lbf) for nut 

2. Hook the tool on the hexagonal portion of the drive belt tensioner bracket and operate drive belt tensioner 3 times with full stroke.
   NOTE: Take 3 seconds or more for 1 full stroke.

Torque: 9 N.m (92 kgf.cm, 80 in.lbf) 

1. Clean the crankshaft pulley inside.
2. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
3. Using SST, install the pulley bolt. SST 09213-70011, 09330-00021
   Fig 18: Using SSTs To Install Crankshaft Pulley

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   Torque: 138 N.m (1,409 kgf.cm, 102 ft.lbf) 

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 19: Collapsing Chain Tensioner Plunger
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the O-ring to the chain tensioner.
3. Push the chain tensioner into the timing chain cover, and install the 2 nuts.
   Fig 20: Installing Timing Chain Tensioner

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   Torque: 9 N.m (92 kgf.cm, 80 in.lbf) 

   NOTE:

   • In case that the hook is released while pushing in, apply the hook again and push the tensioner in.
   • Pay attention not to catch the O-ring as it is built in the chain tensioner previously.

1. Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook.
   Fig 21: Turning Crankshaft To Release Plunger Knock Pin

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2. Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.
   Fig 22: Confirming Plunger Is Pushing Slipper

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   NOTE: If the plunger does not spring out, press the slipper into the chain tensioner with a screwdriver or your finger so that the hook is released from the knock pin and the plunger springs out.

   Fig 23: Using Finger To Release Tensioner Hook From Knock Pin

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1. Turn the crankshaft pulley, and align its groove with timing mark 0 of the timing chain cover.
   NOTE: Always turn the crankshaft clockwise.
2. Check that the point marks of the camshaft timing sprocket and VVT timing sprocket are in straight line on the timing chain cover surface as shown.
   Fig 24: Aligning Camshaft Timing Marks

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

1. Connect the knock sensor connector, crankshaft position sensor connector and oil pressure sensor wire bracket to the oil dipstick guide.
   Fig 25: Installing Oil Dipstick Guide

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2. Install a new O-ring to the oil dipstick.
3. Install the oil dipstick and guide with the nut.

   Torque: 13 N.m (133 kgf.cm, 10 ft.lbf) 

1. Remove any old packing (FIPG) material.
2. Apply seal packing to 2 locations as shown.
   Fig 26: Applying Seal Packing To Specified Areas

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Seal packing: Part No. 08826-00080 or equivalent 

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 and engine wire bracket with the 9 bolts, 2 seal washers and 2 nuts. Uniformly tighten the bolts and nuts in the several passes, in the sequence shown.
   Fig 27: Identifying Cylinder Head Cover Torque Sequence

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   Torque: 

   1. 11 N.m (113 kgf.cm, 8 ft.lbf) for w/o washer 
   2. 9 N.m (92 kgf.cm, 80 in.lbf) for w/ washer 

5. Connect the noise filter.
6. Disconnect the heated oxygen sensor (bank 1 sensor 1) connector.
7. Connect the 2 PCV hoses to the cylinder head cover.

1. Install the engine mounting insulator with the 3 bolts and 3 nuts.
   Fig 28: Installing Engine Mounting Insulator

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   Torque: 52 N.m (530 kgf.cm, 38 ft.lbf) 

2. Remove the jack.

Install the No. 2 cylinder head cover with the 2 nuts and 2 clips.

Fig 29: Installing Drive Belt Idler

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Torque: 36 N.m (370 kgf.cm, 27 ft.lbf)