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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)

NOTICE:
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.





NOTICE:
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 Installation

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 (for Automatic Transmission)





33. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission)





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

Reassembly
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