Timing Chain: Installation

1. Install the camshaft timing sprocket.
   1. Face the timing mark of the sprocket outward.
   2. Align the camshaft knock pin with the knock pin groove on the sprocket side with the timing mark, and slide on the timing sprocket.
      Fig 1: Identifying Timing Mark

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   3. Temporarily install the timing sprocket set bolt.
   4. Hold the hexagon wrench head portion of the exhaust camshaft with a wrench, and tighten the bolt.

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

      Fig 2: Holding Exhaust Camshaft With A Wrench

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2. Install the VVT timing sprocket.
   1. Holding the timing sprocket in the position where the timing sprocket pin groove is slightly to right of the camshaft pin looking from the front side, install the timing sprocket to the camshaft, lightly pressing and turning it counterclockwise. Check that there is virtually no clearance between the timing sprocket and camshaft flange.
      NOTE: Be careful not to turn the timing sprocket clockwise when installing it.
   2. Temporarily install the timing sprocket set bolt.
   3. Hold the hexagon wrench head portion of the intake camshaft with a wrench.
   4. Take care to install the timing sprocket with the bolt.

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

   5. Check that the valve timing controller turns clockwise and that it is locked securely when the lock pin in hole is at the locking point.
      Fig 3: Identifying Timing Mark On Timing Sprocket

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1. Turn the hexagonal wrench head portion of the camshafts, and align the timing marks of the camshaft timing sprocket and VVT timing sprocket with the timing marks of No. 1 and No. 2 bearing caps as shown in the illustration.
   Fig 4: Identifying Timing Marks On Camshaft Timing Sprockets

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2. Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward.
   Fig 5: Turning Crankshaft Using Crankshaft Pulley Bolt

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Install the damper with the 2 bolts.

Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) 

Fig 6: Installing Chain Vibration Damper

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Align the sprocket set key with the key groove of the sprocket, slide on the sprocket.

1. Install the timing chain on the crankshaft timing sprocket with the blue or orange mark link aligned with the timing mark on the crankshaft timing sprocket.
   Fig 7: Installing Timing Chain On Crankshaft Timing Sprocket

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2. Install the timing chain on the camshaft timing sprocket and VVT timing sprocket with the gold or yellow mark links aligned with the timing marks on the camshaft timing sprocket and VVT timing sprocket.
   Fig 8: Installing Timing Chain On Camshaft Timing Sprockets

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Install the timing chain guide with the bolt.

Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) 

Fig 9: Installing Timing Chain Guide

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1. Install the slipper with the bolt.

   Torque: 19 N.m (194 kgf.cm, 14 ft.lbf) 

2. Check that the slipper is hold on the cylinder block stopper.
   Fig 10: Installing Chain Tensioner Slipper

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Install the plate with the F mark facing forward.

Fig 11: Installing Crank Angle Sensor Plate With F Mark Facing Forward

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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 and cylinder head/block/crank case. See Fig 12.
   • 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, see Fig 12.

   Seal packing: Part No. 08826-00080 or equivalent 

   • Install a nozzle that has been cut to a 3 to 4 mm (0.12 to 0.16 in.) opening.

   HINT:

   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.
     Fig 12: Installing Timing Chain Cover

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply seal packing to 2 locations as shown, see Fig 13.

   Seal packing: Part No. 08826-00080 or equivalent 

   • Install a nozzle that has been cut to a 2 mm (0.08 in.) opening.

     HINT:

     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.
     Fig 13: Applying Seal Packing

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the timing chain cover with the 14 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

   Torque: 

   9.0 N.m (92 kgf.cm, 80 in.lbf) for bolt A 

   21 N.m (214 kgf.cm, 15 ft.lbf) for bolt B 

   43 N.m (439 kgf.cm, 32 ft.lbf) for bolt C 

   43 N.m (439 kgf.cm, 32 ft.lbf) for bolt D 

   9.0 N.m (92 kgf.cm, 80 ft.lbf) for nut 

   HINT:

   Bolt length:

   BOLT LENGTH
   
   

   Bolt A	30 mm (1.18 in.) length for 10 mm head
   Bolt B	30 mm (1.18 in.) length for 12 mm head
   Bolt C	40 mm (1.57 in.) length for 14 mm head
   Bolt D	65 mm (2.56 in.) length for 14 mm head

   Fig 14: Identifying Location Of Timing Chain Cover Fasteners

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a Torx® socket wrench (E10), install the stud bolt for the drive belt tensioner.

   Torque: 21.5 N.m (219 kgf.cm, 15.8 in.lbf) 

   Fig 15: Installing Stud Bolt Using Torx Socket Wrench

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Install the drive belt tensioner with the bolt and nut.

Torque: 59.5 N.m (607 kgf.cm, 44 ft.lbf) 

Fig 16: Installing Drive Belt Tensioner

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1. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
2. Using SST, install the pulley bolt.

   SST 09213-54015, 09330-00021

   Torque: 180 N.m (1,836 kgf.cm, 132 ft.lbf) 

   Fig 17: Installing Crankshaft Pulley

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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 18: Installing Chain Tensioner

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2. Place a new gasket on the timing chain cover with portion A facing as shown.
   Fig 19: Placing Gasket On Timing Chain Cover

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3. Push the chain tensioner into the timing chain cover, and install the 2 nuts.

   Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) 

   Fig 20: Pushing Chain Tensioner Into Timing Chain Cover

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1. Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook.
   Fig 21: Setting Chain Tension (1 Of 2)

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2. Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.
   Fig 22: Setting Chain Tension (2 Of 2)

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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.
   Fig 23: Aligning Timing Marks Crankshaft Pulley & Timing Chain Cover

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2. Check that the timing marks of the camshaft timing sprocket and VVT timing sprocket are aligned with the timing marks of the No. 1 and No. 2 bearing caps as shown in the illustration.

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

   Fig 24: Checking Timing Marks Of Camshaft Timing Sprockets

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1. Remove any old packing (FIPG) material.
2. Apply seal packing to 2 locations as shown, see Fig 25.

   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.

   HINT:

   Part must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.

   Fig 25: Applying Seal Packing To 2 Locations

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the cylinder head cover with the 8 bolts and 2 nuts.

   Torque: 11 N.m (112 kgf.cm, 8 ft.lbf) 

   Fig 26: Installing Cylinder Head Cover

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5. Connect the 2 PCV hoses to the cylinder head cover.