FUEL INJECTION PUMP INSTALLATION

1. Install a new gasket and venturi.

2. 

   Connect the throttle control motor connector.

3. 

   Connect the throttle open switch connector.

1. 

   Install a new gasket and intake air connector with the bolt and 3 nuts.

   Torque:

   bolt

   18 N*m  { 184 kgf*cm, 13 ft.*lbf }

   Nut

   12 N*m  { 122 kgf*cm, 9 ft.*lbf }

2. Connect the turbo pressure sensor connector.

3. Connect the ventilation hose.

If there are any defects as shown in the illustrations, check the following points:

1. 

   If there is premature parting:

   
   

   • Check for proper installation.

   • Check the timing cover gasket for damage and proper installation.

2. If the belt teeth are cracked or damaged, check if either camshaft is locked.

3. If there is noticeable wear or cracks on the belt face, check if there are nicks on the side of the idler pulley lock and water pump.

4. If there is wear or damage to only one side of the belt, check the belt guide and the alignment of each pulley.

5. If there is noticeable wear on the belt teeth:

   
   

   • Check the timing cover for damage.

   • Check that the gasket has been installed correctly.

   • Check for foreign matter on the pulley teeth.

   If necessary, replace the timing belt.

1. 

   Visually check the seal portion of the timing belt idler No.1 for oil leakage.

   If leakage is found, replace the timing belt idler No.1.

2. Check that the timing belt idler No.1 turns smoothly.

   If necessary, replace the timing belt idler No.1.

1. 

   Measure the free length of the tension spring.

   Free length
   44.4 to 45.4 mm (1.748 to 1.787 in.)

   If the free length is not as specified, replace the tension spring.

2. Measure the tension of the tension spring at the specified installed length.

   Installed tension
   53 to 59 N (5.42 to 5.98 kgf, 11.9 to 13.2 lbf) at 52.1 mm (2.051 in.)

1. 

   Remove the 6 bolts and tension spring bracket.

2. Remove the water pump and gasket.

1. 

   Using the crankshaft pulley bolt, align its groove with the timing pointer by turning the crankshaft clockwise.

   Note

   Do not turn the crankshaft pulley counterclockwise.

2. 

   Set the timing and drive pulleys at each position.

   Note

   
   

   • The engine should be cold.

   • When turning the crankshaft or camshaft, the valve heads will hit against the piston top. Do not turn them more than necessary.

1. 

   Remove any oil or water on each pulleys, and keep them clean.

2. Install the timing belt on the crankshaft timing pulley and timing belt idlers.

3. 

   Using SST, slightly turn the injection pump drive pulley clockwise. Hang the timing belt on the pulley, and align the timing marks of the drive pulley and timing belt case.

   SST

   09960-10010   ( 09962-01000, 09963-01000 )

4. 

   Using SST, slightly turn the camshaft timing pulley clockwise. Hang the timing belt on the timing pulley, and align the timing marks of the timing pulley and timing belt case.

   SST

   09960-10010   ( 09962-01000, 09963-01000 )

5. Check that the timing belt has tension between the injection pump drive and camshaft timing pulleys.

6. Install the timing belt on the timing belt idler No.2.

1. 

   Loosen the timing belt idler No.1 bolt (A), and stretch the timing belt.

2. Slowly turn the crankshaft pulley 2 revolutions from TDC to TDC.

   Note

   Always turn the crankshaft clockwise.

3. 

   Check each pulley aligns with the timing marks as shown in the illustration.

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

4. Tighten the timing belt idler No.1 bolt (A).

   Torque:

   44 N*m  { 450 kgf*cm, 33 ft.*lbf }

1. 

   Install the belt guide with the cup side facing outward.

1. Remove the 2 nuts and wire harness clamp bracket.

2. 

   Install the 2 gaskets to the timing belt cover.

3. 

   Install the timing belt cover with the 11 bolts.

   Torque:

   11 N*m  { 105 kgf*cm, 8 ft.*lbf }

4. Install the 2 nuts and wire harness clamp bracket.

1. Align the pulley set key with the key groove of the pulley, and slide the pulley to the crankshaft.

2. 

   Using SST, install the new pulley bolt.

   SST

   09213-54015   ( 91651-60855 )

   09330-00021

   Torque:

   235 N*m  { 2,400 kgf*cm, 173 ft.*lbf }

1. 

   w/o Air conditioning:

   
   

   1. Install the vane pump drive pulley and vane pump pulley spacer with the 4 bolts.

      Torque:

      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

2. w/ Air conditioning:

   
   

   1. Install the 2 vane pump drive pulleys with the 4 bolts.

      Torque:

      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

1. Temporarily install the compressor mounting bracket with the 4 bolts.

2. 

   Using several steps, uniformly install and tighten the 4 bolts in the sequence shown in the illustration.

   Torque:

   85 N*m  { 870 kgf*cm, 63 ft.*lbf }

3. 

   Temporarily tighten the bolt and spacer.

4. 

   Temporarily install the compressor mounting bracket with the 3 bolts.

5. Using several steps, uniformly install and tighten the 3 bolts in the sequence shown in the illustration.

   Torque:

   47 N*m  { 475 kgf*cm, 36 ft.*lbf }

1. 

   Install the V belt.

2. Using a bar, adjust the tension of the V belt.

3. Tighten the bolts A and B.

   Torque:

   Bolt A

   75 N*m  { 765 kgf*cm, 55 ft.*lbf }

   Bolt B

   18 N*m  { 185 kgf*cm, 13 ft.*lbf }

4. Check the tension of the V belt. Click here

1. 

   Install the V belt.

2. Tightening the bolt C, adjust the tension of the V belt.

3. Tighten the bolts A and B.

   Torque:

   Bolt A

   75 N*m  { 765 kgf*cm, 55 ft.*lbf }

   Bolt B

   18 N*m  { 185 kgf*cm, 13 ft.*lbf }

4. Check the tension of the V belt. Click here

1. 

   Install the V belt.

2. Tightening the bolt B, adjust the tension of the V belt.

3. Tighten nut A.

   Torque:

   39 N*m  { 400 kgf*cm, 29 ft.*lbf }

4. Check the tension of the V belt. Click here

1. 

   Install the V belt.

2. Using a bar, adjust the tension of the V-ribbed belt.

3. Tighten the bolt A and nut B.

   Torque:

   Bolt (A)

   48 N*m  { 489 kgf*cm, 35 ft.*lbf }

   Nut (B)

   64 N*m  { 635 kgf*cm, 47 ft.*lbf }

4. Check the tension of the V belt. Click here

1. Fill the radiator reservoir assembly with coolant to the top of the inlet.

   Standard Capacity
   Item Specified Condition w/o Heater 12.3 liters (13.0 US qts, 10.8 Imp. qts) w/ Front Heater 13.3 liters (14.1 US qts, 11.7 Imp. qts) w/ Front and Rear Heaters 15.3 liters (16.2 US qts, 13.5 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).

2. 

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

3. 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.

4. 

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