FUEL INJECTION PUMP INSTALLATION

Using a union nut wrench, install the 4 injection pipes.

Torque:

24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }

Secure the injection pipes with the 2 upper pipe clamps and 2 nuts.

Torque:

5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

Place a new gasket and the venturi on the intake manifold.

Fix the intake pipe in place with the 2 bolts and clamp.

Torque:

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

6.0 N*m  { 61 kgf*cm, 53 in.*lbf, for clamp }

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

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.

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

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.

Visually check the seal portion of the No. 1 timing belt idler for oil leakage. If leakage is found, replace the No. 1 timing belt idler.

Check that the No. 1 timing belt idler turns smoothly. If necessary, replace the No. 1 timing belt idler sub-assembly.

Measure the free length of the tension spring.

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

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

Turn the pulley, and check that the pump bearing moves smoothly and quietly.

If it moves roughly or noisily, replace the water pump assembly.

Check that the valve lifters on the No. 1 cylinder are loose and valve lifters on the No. 4 are tight.

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

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

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

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

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

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

Torque:

44 N*m  { 450 kgf*cm, 33 ft.*lbf }

Install 2 new gaskets to the timing belt cover.

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

w/o Air conditioning:

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 }

w/ Air conditioning:

Install the vane pump drive and No. 2 crankshaft pulleys with the 4 bolts.

Torque:

18 N*m  { 184 kgf*cm, 13 ft.*lbf }

Temporarily install the compressor mounting bracket with the 4 bolts.

Install the compressor with the 4 bolts.

Torque:

50 N*m  { 510 kgf*cm, 37 ft.*lbf }

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

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 }

Check the deflection of the V belt Click here.

Tightening the bolt C, adjust the deflection of the V belt.

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 }

Check the deflection of the V belt Click here.

Install the shroud together with the coupling fan between the radiator and engine.

Install the fluid coupling fan to the fan pulley with the 4 nuts.

Tighten the nuts as much as possible by hand.

Attach the shroud's claws to the radiator as shown in A in the illustration.

Install the shroud with the 2 bolts.

Torque:

5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

Install the fan and generator V belt, cooler compressor V belt and vane pump V belt Click here.

Tighten the 4 nuts of the fluid coupling fan.

Torque:

19 N*m  { 194 kgf*cm, 14 ft.*lbf }

Connect the No. 1 and No. 2 water by-pass hoses to the tank upper and lower.

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

Tighten nut A.

Torque:

39 N*m  { 400 kgf*cm, 29 ft.*lbf }

Check the tension of the V belt Click here.

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

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 }

Check the tension of the V belt Click here.

Tighten the radiator drain cock plug by hand.

Tighten the cylinder block drain cock plug.

Torque:

57 N*m  { 581 kgf*cm, 42 ft.*lbf }

Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

If the coolant level drops below the FULL line, add TOYOTA SLLC to the FULL line.

Install the radiator reservoir cap.

Bleed air from the cooling system.

1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.

2. Maintain the engine speed at 2,500 to 3,000 rpm.

3. Press the inlet and outlet radiator hoses several times by hand to bleed air.

   CAUTION:

   When pressing the radiator hoses:

   
   

   • Wear protective gloves.

   
   

   • Be careful as the radiator hoses are hot.

   
   

   • Keep your hands away from the radiator fan.

4. Stop the engine and wait until the coolant cools down to ambient temperature.

   CAUTION:

   Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.