Installation
2UZ-FE ENGINE MECHANICAL: TIMING BELT:
INSTALLATION
1. INSTALL NO. 2 TIMING BELT IDLER SUB-ASSEMBLY
(a) Install the idler with the bolt.
Torque: 35 Nm (357 kgf-cm, 26 ft-lbf)
2. INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY
(a) Using a 10 mm hexagon wrench, install the plate washer and idler with the bolt.
Torque: 35 Nm (357 kgf-cm, 26 ft-lbf)
3. INSTALL TIMING BELT
(a) Set the No. 1 cylinder to TDC/compression.
(1) Turn the hexagonal portion of the camshaft to align the timing marks of the camshaft timing pulleys and timing belt plates.
HINT: By turning the camshaft timing pulleys clockwise as follows, installation of the timing pulleys will be easy:
1/2 tooth turn for the left bank camshaft timing pulley
1 tooth turn for the right bank camshaft timing pulley
(2) Using the pulley set bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body.
(b) Install the timing belt.
(1) Remove any oil or water from each pulley, and keep them clean.
NOTE: Only wipe the pulleys. Do not use any cleansing agent on the pulleys.
(2) Face the front mark (arrow) on the timing belt forward.
(3) Set the timing belt on the crankshaft timing pulley.
HINT: Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
(4) Set the timing belt on the No. 2 timing belt idler.
(5) Set the timing belt on the camshaft timing pulley (for bank 1).
HINT: Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley.
(6) Set the timing belt on the water pump pulley.
(7) Set the timing belt on the camshaft timing pulley (for bank 2).
HINT: Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley.
(8) Set the timing belt on the No. 1 timing belt idler.
(c) Install the belt tensioner.
(1) Using a press, slowly press in the push rod using 981 to 9807 N (100 to 1000 kgf, 220.5 to 2204.7 lbf) of force.
(2) Align the holes of the push rod and housing, and pass a 1.5 mm hexagon wrench through the holes to keep the setting position of the push rod.
(3) Release the press.
(4) Install the dust boot to the belt tensioner.
(5) Temporarily install the belt tensioner with the 2 bolts.
(6) Tighten the 2 bolts.
Torque: 26 Nm (265 kgf-cm, 19 ft-lbf)
(7) Using pliers, remove the 1.5 mm hexagon wrench from the timing belt tensioner.
4. CHECK NO. 1 CYLINDER TO TDC / COMPRESSION
(a) Using the pulley set bolt, slowly turn the crankshaft pulley 2 revolutions from the TDC to TDC.
NOTE: Always turn the crankshaft pulley clockwise.
(b) Check that each pulley is aligned with each timing mark as shown in the illustration.
If the timing marks are not aligned, remove the timing belt and reinstall it.
(c) Remove the pulley set bolt.
5. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE
(a) Install the sensor plate as shown in the illustration.
NOTE: Take care not to install it in a wrong direction.
6. INSTALL NO. 1 TIMING BELT COVER
(a) Install the cover spacer and gasket.
(b) Install the timing belt cover with the 4 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
7. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the crankshaft pulley.
(b) Using SST and a hammer, tap in the crankshaft pulley.
SST: 09223-46011
(c) Using SST, install the pulley set bolt.
SST: 09213-70011
09213-70020
SST: 09330-00021
Torque: 245 Nm (2498 kgf-cm, 181 ft-lbf)
8. INSTALL FAN BRACKET SUB-ASSEMBLY
(a) Install the fan bracket with the 2 bolts and 2 nuts.
for nut A, bolt B - Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)
for nut C, bolt D - Torque: 32 Nm (326 kgf-cm, 24 ft-lbf)
9. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(a) Install the belt tensioner with the bolt and 2 nuts.
Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)
10. INSTALL NO. 2 TIMING BELT COVER SUB-ASSEMBLY
(a) Install the timing belt cover and fit the claws and pins into each part.
(b) Install the 2 bolts.
Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)
11. INSTALL NO. 3 TIMING BELT COVER SUB-ASSEMBLY LH
(a) Pass the camshaft position sensor wire through the cover hole.
(b) Install the cover with the 4 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
(c) Install the wire grommet to the belt cover.
(d) Connect the sensor connector.
(e) Install the sensor wire to the wire clamps on the cover.
(f) Connect the engine wire to the 2 wire clamps on the cover.
12. INSTALL NO. 3 TIMING BELT COVER SUB-ASSEMBLY RH
(a) Install the cover with the 3 bolts and nut.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
13. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a) Install the idler pulley and cover plate with the bolt.
Torque: 39 Nm (398 kgf-cm, 29 ft-lbf)
14. INSTALL OIL COOLER PIPE
(a) Using needle-nose pliers, grip the claws of the clamps and slide the clamps to connect the 3 water by-pass hoses.
(b) Install the oil cooler pipe with the cap nut and bolt.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
15. CONNECT COOLER COMPRESSOR ASSEMBLY
(a) Connect the compressor. Then install it and the No. 1 compressor stay with the nut and 3 bolts.
for bolt - Torque: 47 Nm (479 kgf-cm, 35 ft-lbf)
for nut - Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)
(b) Connect the connector.
16. INSTALL GENERATOR ASSEMBLY (Installation)
17. CONNECT VANE PUMP ASSEMBLY
(a) Connect the vane pump with the nut and 2 bolts.
Torque: 28 Nm (286 kgf-cm, 21 ft-lbf)
(b) Connect the connector.
18. INSTALL FLUID COUPLING ASSEMBLY
(a) Set the fan pulley to the fan bracket.
(b) Set the fan together with the fan shroud into the vehicle.
- Be careful not to damage the radiator core.
- Make sure to attach the 2 claws of the fan shroud to the vehicle.
(c) Temporarily install the fan to the fan pulley with the 4 fluid coupling nuts.
(d) Install the fan shroud with the 2 bolts.
Torque: 6.5 Nm (66 kgf-cm, 58 in-lbf)
(e) Tighten the 4 fluid coupling nuts.
Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)
19. INSTALL FAN AND GENERATOR V BELT (Installation)
20. INSTALL RADIATOR HOSE OUTLET
21. INSTALL RADIATOR HOSE INLET
22. INSTALL AIR CLEANER ASSEMBLY (Installation)
23. INSTALL AIR CLEANER HOSE ASSEMBLY (Installation)
24. INSTALL THROTTLE BODY COVER SUB-ASSEMBLY (Installation)
25. ADD ENGINE COOLANT (Service and Repair)
26. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE: Some systems need to be initialized after the cable is reconnected (Repair Instruction - Initialization).
27. INSPECT FOR COOLANT LEAK (Testing and Inspection)
28. INSPECT IGNITION TIMING (Engine)
29. INSPECT ENGINE IDLE SPEED (Engine)
30. INSTALL NO. 1 ENGINE UNDER COVER (Replacement)