TIMING BELT INSTALLATION

INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY
1. Using a 10 mm hexagon wrench, install a new washer and the timing belt idler with the bolt.
  
  Torque:
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
  
  Note
  
  Do not reuse the washer.
2. Check that the idler pulley moves smoothly by hand.
  
  If it does not move smoothly, check the idler sub-assembly and washer.
INSTALL TIMING BELT
1. Check that the timing marks are aligned as shown in the illustration.
  
  Text in Illustration
  
  *a Timing Marks
  
  Tech Tips
  
  If reusing the timing belt, align the points marked during removal, and install the belt with the direction arrow pointing in the direction of engine revolution.
  Note
  - The engine should be cold.
  - When turning the crankshaft, the valve heads will hit against the piston's top position. Do not turn it more than necessary.
2. Install the timing belt to the pump drive shaft pulley, camshaft timing pulley and No. 1 timing belt idler in sequence.
3. Place the tensioner upright. Then set the press to the top of the tensioner.
  Note
  
  Do not scratch or deform the rod end.
  
  Press in the tensioner rod upward.
  
  Protect the tip of the push rod with a cloth in order to prevent damage.
4. Using a press, slowly push in the push rod using 981 to 9807 N (100 to 1000 kgf, 220 to 2205 lbf) of force.
  
  Note
  
  Do not impose a load of over 9807 N (1000 kgf, 2205 lbf) to the push rod.
5. Align the holes of the push rod and housing. Then pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.
6. Install the timing belt tensioner with the 2 bolts while pushing the idler pulley toward the timing belt.
7. Tighten the 2 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
  
  Note
  
  Uniformly tighten the bolts in order to avoid malfunction of the timing belt tensioner.
8. Remove the 1.27 mm hexagon wrench from the tensioner.
9. Text in Illustration
  
  *a Matchmarks
  
  *b Timing Marks
  
  Turn the crankshaft clockwise 720° and check that the timing marks are aligned as shown in the illustration.
INSTALL NO. 1 TIMING BELT COVER
1. Install the timing belt cover with the 6 bolts (A).
  
  Torque:
  
  6.0 N*m { 61 kgf*cm, 53 in.*lbf }
2. Install the wire harness clamp.
3. Install the water hose clamp with the bolt (B).
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
INSTALL FAN PULLEY
1. Install the fan pulley onto the water pump.
INSTALL FAN SHROUD
1. Temporarily install the fan shroud together with the fan with fluid coupling.
2. Install the fan shroud with the 2 bolts.
  
  Torque:
  
  7.0 N*m { 71 kgf*cm, 62 in.*lbf }
3. Connect the outlet radiator hose onto the fan shroud.
4. Connect the reserve tank hose onto the fan shroud.
INSTALL FLUID COUPLING ASSEMBLY
1. Temporarily tighten the fluid coupling with the 4 nuts.
2. Install the fan and generator V belt Click here.
3. Fully tighten the 4 nuts.
  
  Torque:
  
  23 N*m { 235 kgf*cm, 17 ft.*lbf }
INSTALL INLET RADIATOR HOSE
Text in Illustration

*a Upper

*b Left
1. Install the inlet radiator hose, as shown in the illustration, with the 2 hose clamps.
INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY (for Double Cab)
1. Install the engine service hole sub cover with the 7 bolts.
  
  Torque:
  
  12 N*m { 120 kgf*cm, 9 ft.*lbf }
INSTALL PARKING BRAKE LEVER ASSEMBLY (for Double Cab)
1. Install the parking brake lever with the 4 bolts.
  
  Torque:
  
  17 N*m { 175 kgf*cm, 13 ft.*lbf }
2. Connect the connector.
INSTALL TRANSMISSION FLOOR SHIFT ASSEMBLY (for Double Cab)
1. Install the transmission floor shift with the 4 bolts.
  
  Torque:
  
  18 N*m { 185 kgf*cm, 13 ft.*lbf }
INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (for Double Cab)
1. Install the floor shift cable transmission control select with clip and washer.
2. Install a new clip.
INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (for Double Cab)
1. Install the floor shift cable transmission control shift with the nut and washer.
  
  Torque:
  
  12 N*m { 120 kgf*cm, 9 ft.*lbf }
2. Install a new clip.
INSTALL NO. 1 FRONT FLOOR MAT REAR (for Double Cab)
INSTALL FRONT FLOOR PANEL BRACE (for Double Cab)
1. Install the front floor panel brace with the 3 clips.
INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Double Cab)
INSTALL PARKING BRAKE HOLE COVER (for Double Cab)
1. Install the parking brake hole cover with the screw.
INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab)
1. Install the front door scuff plate LH with the 4 screws.
INSTALL FRONT SEAT ASSEMBLY LH (for Double Cab)
1. Install the front seat LH with the 4 bolts.
  
  Torque:
  
  39 N*m { 400 kgf*cm, 29 ft.*lbf }
2. Connect the connector.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque:

6.4 N*m { 65 kgf*cm, 56 in.*lbf }

Text in Illustration
*a	Timing Marks

Text in Illustration
*a	Matchmarks
*b	Timing Marks

Text in Illustration
*a	Upper
*b	Left

ADD ENGINE COOLANT

Pour coolant into the radiator until it overflows.

Capacity

Specification	Capacity
w/o Heater	9.8 liters (10.3 US qts, 8.6 Imp. qts)
w/ Front Heater	10.7 liters (11.3 US qts, 9.4 Imp. qts)
w/ Front and Rear Heater	11.5 liters (12.2 US qts, 10.1 Imp. qts)

Note

Do not substitute plain water for engine coolant.

Tech Tips

Use of improper coolants may damage the engine cooling system.
Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).

Check the coolant level inside the radiator by squeezing the inlet and outlet radiator hoses several times by hand.

If the coolant level goes down, add coolant.
Install the radiator cap securely.
Slowly pour coolant into the radiator reservoir until it reaches the FULL line.
Warm up the engine until the thermostat opens.
1. While the thermostat is open, circulate the coolant for several minutes.
  
  Tech Tips
  
  The thermostat open timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.
Maintain the engine speed at 2000 to 2500 rpm.
Squeeze the inlet and outlet radiator hoses several times by hand while warming up the engine to bleed the air.
CAUTION:
- Wear protective gloves.
- Be careful as the radiator hoses are hot.
- Keep your hands away from the fan.
Stop the engine and wait until the coolant cools down.
Remove the radiator cap and check the coolant level inside the radiator.
If the coolant level is below the full level, repeat the operation until the coolant level remains at the full level.
Check the coolant level inside the radiator reservoir tank again.

If it is below the full level, add coolant.

INSPECT FOR COOLANT LEAK
1. Remove the radiator cap.
  
  CAUTION:
  
  To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.
2. Text in Illustration
  
  *1 Radiator Cap Tester
  
  Fill the radiator with coolant and attach a radiator cap tester.
3. Warm up the engine.
4. Pump it to 118 kPa (1.2 kgf/cm², 17.1 psi), then check that the pressure does not drop.
  
  If the pressure drops, check the hoses, radiator and water pump for leakage. If there are no signs of external coolant leakage, check the heater core, cylinder block and head.
5. Reinstall the radiator cap.
INSTALL ENGINE SIDE COVER SUB-ASSEMBLY LH
1. for Double Cab:
  
  Install the engine side cover LH with the 4 bolts.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
2. for Single Cab:
  
  Install the engine side cover LH with the 3 bolts.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL ENGINE SIDE COVER SUB-ASSEMBLY RH
1. for Double Cab:
  
  Install the engine side cover RH with the 4 bolts.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
2. for Single Cab:
  
  Install the engine side cover RH with the 3 bolts.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }