Installation

2TR-FE ENGINE MECHANICAL: TIMING CHAIN:

INSTALLATION

1. INSTALL NO.2 CHAIN SUB-ASSEMBLY





(a) Install the chain with its mark links aligned with the timing marks on the crankshaft timing sprocket and balanceshaft timing sprocket.





(b) Bring the other mark link of the crankshaft timing sprocket behind the large timing mark of the balanceshaft drive gear.
(c) Insert the balanceshaft drive gear shaft through the balanceshaft drive gear so that it fits into the thrust plate hole.





(d) Align the small timing mark of the balanceshaft drive gear with the timing mark of the balanceshaft timing gear.
(e) Install the bolt onto the balanceshaft drive gear and tighten it.
Torque: 25 Nm (250 kgf-cm, 18 ft-lbf)





(f) Check that each timing mark is aligned with the corresponding mark link.





2. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Install the chain tensioner with the nut.
Torque: 18 Nm (185 kgf-cm, 13 ft-lbf)

NOTE: Assemble the chain tensioner with the 3.0 mm (0.118 in.) diameter bar installed, then remove the bar after assembly. When doing this, avoid pushing the vibration damper against the chain.





3. INSTALL NO. 3 CHAIN VIBRATION DAMPER
(a) Install the No. 3 chain vibration damper with the 2 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft-lbf)





4. INSTALL CHAIN VIBRATION DAMPER NO.2
(a) Install the chain vibration damper with the bolt.
Torque: 27 Nm (270 kgf-cm, 20 ft-lbf)
(b) Remove the pin from the chain tensioner and release the plunger.





5. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
(a) Install the timing sprocket as shown in the illustration.





6. INSTALL NO. 1 CHAIN VIBRATION DAMPER
(a) Install the vibration damper with the bolt and nut.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
7. INSTALL CHAIN SUB-ASSEMBLY





(a) As shown in the illustration, install the chain onto the sprocket and gear with the painted marks aligned with the timing marks on the sprocket and gear.

HINT:
- The camshaft mark plate is orange.
- The crankshaft mark plate is yellow.





(b) Use a rope to tie the chain of the crankshaft timing sprocket. Tie the rope near the sprocket.

NOTE: After the chain tensioner has been installed, the rope must be removed.

HINT: The rope is tied to prevent gear jumping.





8. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the tensioner slipper with the bolt.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)





9. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
(a) Install a new gasket and the chain tensioner with the bolt and nut.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)





10. INSTALL TIMING CHAIN GUIDE
(a) Install a new O-ring and the chain guide with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
11. INSTALL TIMING CHAIN COVER (Installation)

12. INSTALL OIL PAN SUB-ASSEMBLY





(a) Apply continuous beads of seal packing to the places shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal width:
2 to 3 mm (0.079 to 0.118 in.)

NOTICE:
- Remove any oil from the contact surface.
- Install the crankcase within 3 minutes of applying the seal packing.
- Do not start the engine for at least 2 hours after installation.





(b) Loosely install the oil pan with the 16 bolts and 2 nuts.

HINT: Bolt length:

20 mm (0.79 in.) for bolt A,

40 mm (1.57 in.) for bolt B

(c) Uniformly tighten the 16 bolts and 2 nuts in the sequence shown in the illustration.
Torque: 26 Nm (265 kgf-cm, 19 ft-lbf)





13. INSTALL OIL STRAINER SUB-ASSEMBLY
(a) Install a new gasket and the oil strainer with the 2 bolts and 2 nuts.
Torque: 26 Nm (265 kgf-cm, 19 ft-lbf)
14. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY





(a) Apply continuous beads of seal packing to the places shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal width:
3 to 4 mm (0.118 to 0.157 in.)

NOTICE:
- Remove any oil from the contact surface.
- Install the crankcase within 3 minutes of applying the seal packing.
- Do not start the engine for at least 2 hours after installation.





(b) Provisionally install the oil pan with the 18 bolts and 2 nuts.
(c) Uniformly tighten the 18 bolts and 2 nuts in the sequence shown in the illustration.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
(d) Install a new gasket and the drain plug.
15. INSTALL OIL LEVEL GAGE SUB-ASSEMBLY
16. INSTALL CRANKSHAFT PULLEY (Installation)

17. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (Installation)

18. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET (Removal)

19. INSTALL CAMSHAFT POSITION SENSOR (Installation)

20. INSTALL CRANKSHAFT POSITION SENSOR (Installation)

21. INSTALL IDLE PULLEY ASSEMBLY WITH BRACKET (w/ Air Conditioning System) (Removal)





22. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY
(a) Install the No. 1 idler pulley sub-assembly with the bolt.
Torque: 43 Nm (438 kgf-cm, 32 ft-lbf)
23. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (Installation)

24. INSTALL GENERATOR ASSEMBLY (Service and Repair)

25. INSTALL INTAKE AIR CONNECTOR (Installation)

26. INSTALL REAR END PLATE
(a) Install the rear end plate with the 2 bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)
27. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission) (Installation)

28. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission) (Installation)

29. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission)





30. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission)





31. INSTALL ENGINE ASSEMBLY (Installation)

32. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (Service and Repair)

33. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY





34. INSTALL EXHAUST PIPE ASSEMBLY FRONT (Installation)

35. INSTALL EXHAUST PIPE ASSEMBLY TAIL (Installation)

36. CONNECT ENGINE WIRE
37. CONNECT NO. 1 AIR INJECTION HOSE (Installation)

38. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY (Installation)

39. CONNECT NO. 2 FUEL HOSE (Installation)

40. CONNECT FUEL HOSE (Installation)

41. INSTALL WATER HOSE SUB-ASSEMBLY (Installation)

42. INSTALL RADIATOR HOSE INLET
43. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)





(a) Install the compressor and magnetic clutch with the 4 bolts.
Torque: 21 Nm (214 kgf-cm, 16 ft-lbf)
(b) Connect the compressor and magnetic clutch connector.





(c) Install the bolt shown in the illustration.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
44. INSTALL NO. 2 RADIATOR HOSE





45. INSTALL VANE PUMP ASSEMBLY
(a) Install the vane pump with the 2 bolts.
Torque: 21 Nm (214 kgf-cm, 16 ft-lbf)
(b) Connect the vane pump connector.
46. INSTALL AIR CLEANER CASE
(a) Install the air cleaner case with the 3 bolts.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
47. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
48. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (Installation)

49. INSTALL FAN SHROUD (Installation)

50. INSTALL RADIATOR SUPPORT TO FRAME SEAL LH (Installation)

51. INSTALL BATTERY TRAY
52. INSTALL BATTERY
53. ADD ENGINE OIL (Installation)

54. ADD ENGINE COOLANT (Service and Repair)

55. CHECK FOR ENGINE OIL LEVEL
56. CHECK FOR FUEL LEAKAGE
57. CHECK FOR ENGINE COOLANT LEAKAGE (Testing and Inspection)

58. CHECK FOR OIL LEAKAGE
59. CHECK FOR EXHAUST GAS LEAKAGE
60. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (for 4WD and Pre-Runner)
(a) Install the No. 1 engine under cover with the 4 bolts.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
61. INSTALL NO. 2 ENGINE UNDER COVER SUB-ASSEMBLY (for 4WD and Pre-Runner, Regular Cab)
(a) Install the No. 2 engine under cover with the 4 bolts.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
62. INSTALL HOOD SUB-ASSEMBLY