Installation
1GR-FE ENGINE MECHANICAL: TIMING CHAIN: INSTALLATION
INSTALLATION
1. INSTALL CHAIN TENSIONER SLIPPER
2. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
(a) While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration.
(b) While turning the stopper plate of the tensioner counterclockwise, insert a bar of dia3.5 mm (0.138 in.) into the holes on the stopper plate and tensioner to fix the stopper plate.
(c) Install the chain tensioner with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
3. INSTALL CHAIN SUB-ASSEMBLY
(a) Set the No. 1 cylinder to the TDC / compression.
(1) Align the timing marks of the camshaft timing gears and bearing caps.
(2) Install the crankshaft pulley set bolt, and turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block.
(b) Align the mark link (yellow) with the timing mark of the crankshaft timing gear.
(c) Align the mark links (orange) with the timing marks of the camshaft timing gears, and install the chain.
4. INSTALL NO. 2 CHAIN VIBRATION DAMPER
(a) Instal the 2 No. 2 chain vibration dampers.
5. INSTALL NO. 1 IDLE GEAR SHAFT
(a) Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.
(b) Temporarily install the No. 1 idle gear shaft and No. 1 idle gear with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear shaft with the knock pin groove of the cylinder block.
NOTE: Be careful of the idle gear direction.
(c) Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.
Torque: 60 Nm (612 kgf-cm, 44 ft-lbf)
(d) Remove the bar from the chain tensioner.
6. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Reassembly
7. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY Reassembly
8. INSTALL VVT SENSOR Installation
9. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) Insert the camshaft timing oil control valves to each cylinder head, and tighten the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH Reassembly
11. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Reassembly
12. INSTALL IGNITION COIL ASSEMBLY
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
13. INSTALL INTAKE AIR SURGE TANK Installation
14. INSTALL OIL PAN SUB-ASSEMBLY
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan.
(b) Install a new O-ring to the oil pump.
(c) Apply a continuous bead of seal packing (diameter: 3 to 4 mm (0.12 to 0.16 in.)) to the oil pan as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent
NOTE: Install the oil pan within 3 minutes after applying seal packing. After installing it, the oil pan bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.
(d) Install the oil pan with the 17 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
For bolt A - Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
For bolt B - Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
For bolt C - Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
For nut - Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
HINT:
Each bolt length is as follows:
A: 25 mm (0.98 in.)
B: 45 mm (1.77 in.)
C: 14 mm (0.55 in.)
(e) Install the 4 housing bolts.
Torque: 37 Nm (377 kgf-cm, 27 ft-lbf)
(f) Install the flywheel housing under cover.
15. INSTALL OIL STRAINER SUB-ASSEMBLY
(a) Install a new gasket and the oil strainer with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
16. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pan and No. 2 oil pan.
(b) Apply a continuous bead of seal packing (diameter 3: to 4 mm (0.12 to 0.16 in.)) as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent
NOTE: Install the No. 2 oil pan within 3 minutes after applying seal packing. After installing it, the No. 2 oil pan bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.
(c) Install the No. 2 oil pan with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
17. INSTALL CRANKSHAFT PULLEY
(a) Using SST, install the pulley set bolt.
SST: 09213-54015
91651-60855
SST: 09330-00021
Torque: 250 Nm (2,549 kgf-cm, 184 ft-lbf)
18. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY
(a) Install the idler pulley with the bolt.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)
HINT: "DOUBLE" is marked on the No. 1 idler pulley to distinguish it from the No. 2 idler pulley.
19. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
NOTE: The installation of the No. 2 idler pulleys differs depending on the mark on the No. 2 idler pulleys shown in the illustration.
HINT: Use the same procedure for both No. 2 idler pulleys.
(a) w/ Idler Pulley Cover Plate (PU107013ARMXY3):
(1) Install the idler pulley cover plate, idler pulley and No. 2 idler pulley cover plate with the bolt.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)
NOTICE:
- If it is necessary to replace the pulley or either plate, replace the No. 2 idler pulley cover plate, No. 2 idler pulley and idler pulley cover plate as a set with new parts.
- When replacing parts, make sure to replace the No. 2 idler pulley with a new pulley marked "PU107013ARMXY3".
(b) w/o Idler Pulley Cover Plate (PU107013ARMXY1):
(1) Install the idler pulley and No. 2 idler pulley cover plate with the bolt.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)
NOTICE:
- If it is necessary to replace the pulley or plate, replace both the pulley and plate with a set of new parts that includes a No. 2 idler pulley cover plate, No. 2 idler pulley and idler pulley cover plate.
- When replacing parts, make sure to replace the No. 2 idler pulley with a new pulley marked "PU107013ARMXY3".
20. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(a) Temporarily install the V-ribbed belt tensioner with the 5 bolts.
(b) Install the V-ribbed belt tensioner by tightening the bolt 1 and bolt 2 in the order shown in the illustration.
Torque: 36 Nm (367 kgf-cm, 27 ft-lbf)
(c) Tighten the other bolts.
Torque: 36 Nm (367 kgf-cm, 27 ft-lbf)
HINT:
Each bolt length is as follows:
A: 70 mm (2.76 in.)
B: 33 mm (1.30 in.)
21. INSTALL COOLER COMPRESSOR ASSEMBLY Installation
22. INSTALL GENERATOR ASSEMBLY Installation
23. INSTALL VANE PUMP ASSEMBLY
(a) Install the vane pump with the 2 bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft-lbf)
NOTE: Do not hit the pulley to other parts when installing the vane pump.
(b) Connect the P/S oil pressure switch connector.
24. INSTALL WATER INLET Installation
25. INSTALL OIL LEVEL GAUGE GUIDE
(a) Install a new O-ring to the oil level gauge guide.
(b) Apply a light coat of engine oil to the O-ring.
(c) Push in the oil level gauge guide end into the guide hole of the oil pan.
(d) Install the oil level gauge guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
(e) Install the oil level gauge.
26. INSTALL AIR CLEANER ASSEMBLY Installation
27. CONNECT NO. 2 VENTILATION HOSE
28. INSTALL FLUID COUPLING ASSEMBLY Installation
29. INSTALL FAN AND GENERATOR V BELT Installation
30. FULLY TIGHTEN FLUID COUPLING ASSEMBLY Installation
31. INSTALL RADIATOR SUPPORT SEAL UPPER
32. INSTALL BATTERY
33. INSTALL DIFFERENTIAL CARRIER ASSEMBLY FRONT
HINT:
34. INSTALL POWER STEERING LINK ASSEMBLY
HINT: Installation
35. ADD ENGINE OIL Installation
36. ADD ENGINE COOLANT Service and Repair
37. CHECK FOR ENGINE OIL LEAKS
38. CHECK FOR ENGINE COOLANT LEAKS Service and Repair
39. INSTALL V-BANK COVER
(a) Install the V-bank cover with the 2 nuts.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
40. INSPECT IGNITION TIMING Engine