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 09223-4601 1
   Fig 1: Tapping Timing Pulley Using SST

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1. Apply adhesive 2 or 3 threads from the end of the pivot bolt.
   1. Adhesive: 
   2. 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 & No. 1 Idler Pulley

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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.
   Fig 3: Aligning Installation Mark On Timing Belt

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3. Install the timing belt on the crankshaft timing pulley, the No. 1 idler pulley and the No. 2 idler pulley.

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

Install the belt guide, facing the cup side outward.

Fig 4: Installing Timing Belt Guide

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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 09223-4601 1
   Fig 5: Installing 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.

1. (See  INSTALLATION  ) 

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

Fig 6: Checking Timing Mark Of Crankshaft Pulley Is Aligned

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1. Align the camshaft knock pin with the knock pin grove of the timing pulley, and slide 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 Pulley Bolt Using SST

   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

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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.

Fig 10: Turning RH Camshaft Timing Pulley

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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.
   Fig 11: Pressing In Push Rod Using Press Slowly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.

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

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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: Slowly Turning Crankshaft Pulley

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3. Check that each pulley aligns with the timing marks as shown in the illustration.
   Fig 14: Checking Pulley Aligns With Timing Marks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Using SST, install the pulley bolt.

1. SST 09213-7001 1 (90105-70020), 09330-00021
2. Torque: 245 N.m (2,500 kgf.cm, 181 ft.lbf) 

Fig 15: Tightening Crankshaft Pulley Bolt Using SST

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

1. Torque: 
2. 12 mm head 
   1. 16 N.m (160 kgf.cm, 12 ft.lbf) 
3. 14 mm head 
   1. 32 N.m (330 kgf.cm, 24 ft.lbf) 
   Fig 16: Installing Fan Bracket With 2 Bolts And Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. (See  INSTALLATION  ) 

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

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

Fig 17: Installing No. 2 Timing Belt Cover

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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) 
   Fig 19: Installing LH No. 3 Timing Belt Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.

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

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

1. (See  INSTALLATION  ) 

1. Temporarily install the fan pulley, the fan, fluid coupling assembly with the 4 nuts.
   Fig 20: Installing Fan Pulley

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