TIMING CHAIN INSTALLATION

INSTALL NO.2 CHAIN SUB-ASSEMBLY
1. Install the crankshaft timing sprocket No.2 to the crankshaft.
2. Check that the No.1 cylinder is at TDC and that the weights of the balance shaft No.1 and No.2 are at the bottom side.
3. Install the chain by matching its mark plate with the timing marks on the crankshaft timing sprocket and balance shaft timing sprocket.
4. Fit the other timing mark (yellow) of the crankshaft timing sprocket behind the timing mark (large) of the balance shaft drive gear.
5. Insert the balance shaft drive gear shaft through the balance shaft drive gear so that it fits into the thread hole, then align the small timing mark of the balance shaft drive gear with the timing mark of the balance shaft timing gear (large), install the bolt to the balance shaft drive gear and tighten it.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
6. Check that each timing mark is matched with the corresponding mark link.
  
  Note
  
  Check that the No.1 cylinder is at TDC and that the wights of the balance shaft No.1 and No.2 are at the bottom side.
INSTALL CHAIN TENSIONER ASSEMBLY NO.2
1. Install the chain tensioner assembly No.2 with the nut.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
2. Assemble the chain tensioner with the hexagon wrench (width 1.5 mm) installed.
INSTALL CHAIN VIBRATION DAMPER NO.3
1. Install the chain vibration damper No.3 with the 2 bolts.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
INSTALL CHAIN VIBRATION DAMPER NO.2
1. Install the chain vibration damper No.2 with the bolt.
  
  Torque:
  
  27 N*m { 270 kgf*cm, 20 ft.*lbf }
2. Remove the hexagon wrench from the chain tensioner and release the plunger.
INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
1. Install the crankshaft timing gear to the crankshaft.
INSTALL CHAIN VIBRATION DAMPER NO.1
1. Install the vibration damper with the 2 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL CHAIN SUB-ASSEMBLY
1. As shown in the illustration, install the chain on the sprocket and gear with the painted marks aligned with the timing marks on the sprocket and gear.
  Tech Tips
  
  The camshaft mark plate is orange.
  
  The crankshaft mark plate is yellow.
2. Use a rope to tie the chain of the crankshaft timing sprocket. Tie the rope near the gear.
  
  Note
  
  After the chain tensioner has been installed, the rope must be removed.
  
  Tech Tips
  
  The rope is tied so that the chain will not jump a tooth.
INSTALL CHAIN TENSIONER SLIPPER
1. Install the tensioner slipper with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL CHAIN TENSIONER ASSEMBLY NO.1
1. Install a new gasket and the chain tensioner No.1 with the bolt and nut.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
  
  Note
  
  Remove the hexagon wrench after installing the timing chain guide.
INSTALL TIMING CHAIN GUIDE
1. Install a new O-ring and the chain guide with the 2 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Remove the hexagon wrench from the chain tensioner and release the plunger.
INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
1. Place the timing chain cover on wooden blocks.
2. Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.
  
  SST
  
  09223-50010
  Note
  - Keep the lip free from foreign matter.
  - Do not tap the oil seal at an angle.
INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY

Click here

INSTALL OIL PAN SUB-ASSEMBLY

Apply seal packing in a continuous bead as shown in the illustration.

Seal packing

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal width

2.0 to 3.0 mm (0.079 to 0.118 in.)
Note
- Remove any oil from the contact surface.
- After applying seal packing, put on the oil pan sub-assembly within 3 minutes, and then tighten the bolts and nuts within 15 minutes.
- Do not start the engine for at least 4 hours after installing.
Install a new O-Ring to the bottom of the chain cover plate.

Seal packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal width
2.0 to 3.0 mm (0.079 to 0.118 in.)

Temporarily install the oil pan with the 16 bolts and 2 nuts.

Bolt length
Bolt A
20 mm (0.79 in.)
Bolt B
40 mm (1.57 in.)

Uniformly tighten the 16 bolts and 2 nuts in the sequence shown in the illustration.

Torque:

26 N*m { 265 kgf*cm, 19 ft.*lbf }

INSTALL OIL STRAINER SUB-ASSEMBLY
1. Install a new gasket and the oil strainer with the 2 bolts and 2 nuts.
  
  Torque:
  
  26 N*m { 265 kgf*cm, 19 ft.*lbf }
INSTALL OIL PAN SUB-ASSEMBLY NO.2
1. Apply seal packing in a continuous bead as shown in the illustration.
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal width
  
  3.0 to 4.0 mm (0.118 to 0.157 in.)
  Note
  
  Remove any oil from the contact surface.
  
  After applying seal packing, put on the oil pan sub-assembly within 3 minutes, and then tighten the bolts and nuts within 15 minutes.
  
  Do not start the engine for at least 2 hours after installing.
2. Temporarily install the oil pan with the 18 bolts and 2 nuts.
3. Uniformly tighten the 18 bolts and 2 nuts in the sequence shown in the illustration.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
INSTALL CRANKSHAFT PULLEY
1. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
2. Using SST, install the crankshaft pulley bolt.
  
  SST
  
  09213-54015 ( 91651-60855 )
  
  09330-00021
  
  Torque:
  
  260 N*m { 2,651 kgf*cm, 192 ft.*lbf }
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
1. Install the cylinder head cover gasket and cylinder head gasket No.2 to the cylinder head cover.
2. Remove any old packing (FIPG) material.
3. Apply seal packing as shown in the illustration.
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  Note
  
  Remove any oil from the contact surface.
  
  Install the cylinder head cover sub-assembly within 3 minutes after applying seal packing.
  
  Do not start the engine for at least 4 hours after installing.
4. Temporarily install the head cover with the 19 bolts and 2 nuts.
5. Fully tighten the A bolts.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
6. Fully tighten the B bolts and nuts.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
7. Make sure that the A bolts are completely tighten to the specified torque.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
8. Connect the ventilation hose No.1.
INSTALL IGNITION COIL ASSEMBLY
1. Install the ignition coils with the bolts.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission)

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INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

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INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
1. Temporarily install the belt tensioner with the 2 bolts.
  Tech Tips
  
  Make sure that the belt tensioner is in contact with the engine block.
  
  Check that the bolt holes of the belt tensioner and timing chain cover are aligned.
2. Install the tensioner by tightening the 2 bolts in the order shown in the illustration.
  
  Torque:
  
  Bolt 1
  
  40 N*m { 408 kgf*cm, 30 ft.*lbf }
  
  Bolt 2
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL IDLER PULLEY SUB-ASSEMBLY NO.1
1. Install the idler pulley sub-assembly No.1, collar and pulley plate with the bolt.
  
  Torque:
  
  43 N*m { 438 kgf*cm, 32 ft.*lbf }
  
  Note
  
  Check that the pulley plate and collar are assembled properly to the idler pulley No.1.
INSTALL COMPRESSOR MOUNTING BRACKET NO.1 (w/ Air Conditioning System)
1. Temporarily install the mounting bracket with the 5 bolts.
  
  Tech Tips
  
  Make sure that the mounting bracket is in contact with the engine block at points A shown in the illustration.
2. Install the mounting bracket by tightening the 5 bolts in the order shown in the illustration.
  
  Torque:
  
  Bolt B
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
  
  Except bolt B
  
  45 N*m { 459 kgf*cm, 33 ft.*lbf }
  
  Note
  
  In order to prevent misalignment, which causes belt rattle, tightening of the bolts must be performed in the order shown.
INSTALL GENERATOR ASSEMBLY
1. Install the generator assembly with the 3 bolts.
  
  Torque:
  
  43 N*m { 438 kgf*cm, 32 ft.*lbf }
2. Install the generator wire with the nut to terminal B.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
3. Install the terminal cap.
4. Connect the generator connector.
INSTALL WATER BY-PASS PIPE NO.1
1. Install a new gasket and the water by-pass pipe with the 2 nuts and bolt.
  
  Torque:
  
  Nut
  
  18 N*m { 180 kgf*cm, 13 ft.*lbf }
  
  Bolt
  
  8.0 N*m { 80 kgf*cm, 71 in.*lbf }
INSTALL FAN PULLEY
1. Install the fan spacer and fan pulley with the 4 nuts.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
INSTALL INTAKE MANIFOLD
1. Install a new gasket and the intake manifold with the 5 bolts and 2 nuts.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
2. Connect the ventilation hose No.3.
INSTALL INJECTOR ASSEMBLY
1. Apply a light coat of grease or gasoline to new O-rings and install them to the injector spacers.
  
  Note
  
  Make sure that the O-rings are installed between the parts correctly.
2. Install the injection spacers.
3. Apply a light coat of grease or gasoline to the place where the delivery pipe touches the O-ring.
4. To install the fuel injector into the fuel delivery pipe, push the fuel injector while twisting it right and left.
  Note
  
  Be careful not to twist the O-ring.
  
  After installing the fuel injector, check that it turns smoothly. If not, reinstall it with a new O-ring.
INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
1. Install the 4 spacers to the cylinder head.
2. Install the delivery pipe spacers.
3. Temporarily install the 2 bolts and fuel delivery pipe together with the 4 injectors.
  Note
  
  Do not drop the fuel injector when installing the fuel delivery pipe.
  
  Make sure that the fuel injector turns smoothly.
4. Fully tighten the 2 bolts.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 10 ft.*lbf }
5. Apply a light coat of grease or gasoline to the place where the delivery pipe touches the O-ring.
6. Install the 2 bolts and pressure pulsation damper assembly.
  
  Torque:
  
  8.5 N*m { 87 kgf*cm, 75 in.*lbf }
7. Connect the 2 fuel hoses.
INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY
1. Install a new gasket onto the intake manifold.
  
  Tech Tips
  
  Fit the gasket to the cutout of the intake manifold.
2. Install the throttle body assembly with the 2 bolts and 2 nuts. (A)
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
3. Connect the water by-pass hose. (B)
4. Connect the water by-pass hose No.2. (C)
5. Connect the throttle motor connector. (D)
CONNECT ENGINE WIRE
INSTALL COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)
1. Temporarily install the bolt A to install the compressor.
2. Install the compressor completely by tightening the 4 bolts in the order shown in the illustration.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
  
  Note
  
  In order to prevent misalignment, which causes belt rattle, tightening of the bolts must be performed in the order shown.
3. Connect the suction tube clamp with the bolt.
  
  Torque:
  
  5.4 N*m { 55 kgf*cm, 48 in.*lbf }
4. Connect the compressor connector.
INSTALL OIL LEVEL GAUGE GUIDE
1. Install the gauge guide with the bolt.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY
INSTALL VANE PUMP ASSEMBLY
1. Install the vane pump with the 2 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
2. Connect the PS fluid pressure switch connector.
CONNECT FUEL HOSE NO.2
1. Connect the fuel hose No.2 to the delivery pipe.
CONNECT FUEL HOSE
1. Align the connector and pipe. Push on the connector until the retainer locks with a click sound. Click here
2. Pull the connector to check that the connector is securely connected. Click here
3. Install the connector and lock it with the fuel hose connector cover. Click here
INSTALL INTAKE AIR CONNECTOR
1. Temporarily install the intake air connector to the throttle body assembly.
2. Connect the ventilation hose No.2 and the vacuum hose. (A)
3. Install the intake air connector with the 2 bolts. (B)
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
4. Tighten the 2 hose clamp bolts. (C)
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
5. Tighten the 2 hose clamp bolts. (D)
CONNECT UNION TO CONNECTOR TUBE HOSE
1. Connect the union to connector tube hose to the intake manifold.
CONNECT FUEL VAPOR FEED HOSE ASSEMBLY
1. Connect the fuel vapor feed hose to the VSV.
CONNECT RADIATOR HOSE OUTLET
1. Connect the radiator outlet hose to the clamp.
CONNECT RADIATOR HOSE INLET
1. Connect the radiator inlet hose to the clamp.
INSTALL FAN & GENERATOR V BELT
1. Install the drive belt to the pulleys except the drive belt tensioner pulley.
2. Use the hexagon-shaped part indicated by the arrow in the illustration to move the tensioner pulley downward and then install the drive belt to the tensioner pulley.
  Note
  - The backside of the drive belt should face the tensioner pulley.
  - Check that the drive belt is properly set to each pulley.
3. After a new belt has been installed, check that the tensioner indicator mark is within range A shown in the illustration.
INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY
1. Install the engine service hole sub cover with the 5 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
INSTALL FRONT DOOR SCUFF PLATE RH
INSTALL FRONT SEAT ASSEMBLY RH (for Hi-back Seat Type)
1. Perform the same procedure as above on the opposite side. Click here
INSTALL FRONT SEAT ASSEMBLY RH (for Low-back Seat Type)
1. Perform the same procedure as above on the opposite side. Click here
CONNECT BATTERY NEGATIVE TERMINAL
ADD ENGINE OIL

Seal packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal width
3.0 to 4.0 mm (0.118 to 0.157 in.)

Seal packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

ADD ENGINE COOLANT

Firmly tighten the drain plugs and fill the reservoir tank with coolant to the top of the inlet.
Remove the 2-way that is located near the throttle body.
When air is bled and the coolant drains out, firmly install the 2-way.

Add coolant up to the B line mark in the reservoir tank and install the radiator cap.

Coolant Capacity

Condition	Capacity
w/ front and rear heaters	13.6 liters (14.4 US qts, 12.0 lmp. qts)
w/ front heater	11.6 liters (12.3 US qts, 10.2 lmp. qts)
w/o heater	10.6 liters (11.2 US qts, 9.3 lmp. qts)

Warm up the engine.
After the engine cools down, check that the coolant level is between the LOW and FULL level marks.

INSPECT FOR FUEL LEAKS
1. When using the intelligent tester
  1. Connect the intelligent tester to the DLC3.
  2. Turn the ignition switch to the on position and intelligent tester main switch ON.
    
    Note
    
    Do not start the engine.
  3. Select the Active Test mode on the intelligent tester.
    
    Tech Tips
    
    Please refer to the intelligent tester operator's manual for further details.
2. When not using the intelligent tester.
  1. Disconnect the fuel pump connector.
  2. Using a service wire, connect terminals FP and +B of the relay block.
    
    Note
    
    Pay attention to the terminal connecting position to avoid a malfunction.
  3. Turn the ignition switch to the ON position, and check that the fuel pump operates.
    
    Note
    
    Do not start the engine.
3. Check that there are no fuel leaks anywhere on the fuel system after doing maintenance.
4. Check that the pulsation damper screw rises up when the fuel pump operates.
  
  If operation is not as specified, check the following parts:
  - Fusible link
  - Fuel pump
  - Wiring connections
  - ECM
  - Fuses
5. Turn the ignition switch off.
6. Disconnect the intelligent tester from the DLC3.
INSPECT ENGINE OIL LEAKS
CHECK FOR ENGINE COOLANT LEAKS

CAUTION:

Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
1. Fill the radiator with coolant and attach a radiator cap tester to the radiator.
2. Warm up the engine.
3. Using a radiator cap tester, increase the pressure inside the radiator to 137 kPa (1.4 kgf/cm², 19.9 psi), and check that the pressure does not drop.
  
  Tech Tips
  
  If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.
INSTALL ENGINE SIDE UNDER COVER LH (w/ Engine Side Under Cover LH)
INSTALL ENGINE SIDE UNDER COVER RH (w/ Engine Side Under Cover RH)
INSTALL ENGINE UNDER COVER NO.2 (w/ Engine Under Cover No.2)
INSTALL ENGINE UNDER COVER NO.1 (w/ Engine Under Cover No.1)
CHECK IDLE SPEED AND IGNITION TIMING

Click here
CHECK FUNCTION OF THROTTLE BODY
1. Check the throttle control motor operating sounds.
  1. Turn the ignition switch to the ON position.
  2. When pressing the accelerator pedal, listen to the running sounds of the motor. Make sure no friction noise comes from the motor.
    
    If friction noise exists, replace the throttle body.
2. Check the throttle position sensor.
  1. Connect the intelligent tester to the DLC3.
  2. Turn the ignition switch to the ON position.
  3. Turn the intelligent tester main switch on.
  4. Enter the following menus: Power train / Engine / Data List / Throttle Sensor Position and Throttle Position Sensor Position #2.
  5. Depress the accelerator pedal. When the throttle valve is fully opened, check that the value of the "Throttle Sensor Position" is within the specification.
    
    Standard throttle valve opening percentage
    
    60% or more
    
    Note
    
    When checking the standard throttle valve opening percentage, the shift lever should be in the N position.
    
    Tech Tips
    
    If the percentage is less than 60%, replace the throttle body.
PERFORM INITIALIZATION

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