Installation

1GR-FE ENGINE MECHANICAL: TIMING CHAIN (for 4WD and Pre-Runner): 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 dia 35 mm (0.138 in.) into the holes in 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, 7.4 ft-lbf)

3. INSTALL CHAIN SUB-ASSEMBLY

(a) Set the No. 1 cylinder to TDC/ compression.

(1) Align the timing marks of the camshaft timing gears and bearing caps.

(2) Using the crankshaft pulley set bolt, turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block.

(b) Align the yellow mark link with the timing mark of the crankshaft timing link.

4. INSTALL NO.2 CHAIN VIBRATION DAMPER

(a) Install the 2 chain vibration dampers No. 2.

5. INSTALL IDLE SPROCKET ASSEMBLY

(a) Apply a light coat of engine oil to rotating surface of the idle gear shaft No. 1.

(b) Temporarily install the idle gear shaft No. 1 together with the idle gear shaft No. 2 while aligning the knock pin of the idle gear shaft No. 1 with the knock pin groove of the cylinder block.

NOTICE:
Be careful of the idle gear direction.

(c) Using 10 mm hexagon wrench, tighten the idle gear shaft No. 2.

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 Replacement

7. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY Installation

8. INSTALL VVT SENSOR Installation

9. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Installation

10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH Installation

11. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Installation

12. INSTALL IGNITION COIL ASSEMBLY Installation

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 onto 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

NOTICE:
Install the oil pan within 3 minutes of applying the seal packing. Tighten the oil pan bolts and nuts within 15 minutes of installing the oil pan. Otherwise, the seal packing must be removed and reapplied.

(d) Install the oil pan with the 17 bolts and 2 nuts, and tighten the bolts and nuts uniformly in several steps.

Torque : 10 Nm (102 kgf-cm, 7.4 ft-lbf) for 10 mm (0.39 in.) head

Torque : 21 Nm (214 kgf-cm, 16 ft-lbf) for 12 mm (0.47 in.) head

HINT
Each bolt length is as follows:

(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 oil pan No. 2.

(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

NOTICE:
Install the oil pan No. 2 within 3 minutes of applying the seal packing. Tighten the oil pan No. 2 bolts and nuts within 15 minutes of installing the oil pan No. 2. Otherwise, the seal packing must be removed and reapplied.

(c) Install the oil pan No. 2 with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) for bolts

Torque : 10 Nm (102 kgf-cm, 7.4 ft-lbf) for nut

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 idler pulley No. 1 to distinguish it from the idler pulley No. 2.

19. INSTALL NO.2 IDLER PULLEY SUB-ASSEMBLY

(a) Install the 2 idler pulleys with the 2 bolts.

Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)

20. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

NOTICE:
A bolt in position A is not reusable.

HINT
Each bolt length is as follows:

(a) Use a new bolt in position A.

(b) Finger-tighten the bolts in positions A and E and install the bracket.

(c) Tighten the bolts in positions A and E.

Torque : 36 Nm (267 kgf-cm, 27 ft-lbf)

(d) Tighten the bolts in positions B, C and D.

Torque : 36 Nm (267 kgf-cm, 27 ft-lbf)

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.

(b) Connect the power steering pressure switch connector.

Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)

NOTICE:
Do not hit the pulley with other parts when installing the vane pump.

(c) Connect the power steering pressure switch connector.

24. INSTALL WATER INLET Installation

25. INSTALL OIL LEVEL GAGE GUIDE

(a) Install a new O-ring onto the oil level gauge guide.

(b) Apply a light coat of engine oil to the O-ring.

(c) Push 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 guide.

26. INSTALL AIR CLEANER ASSEMBLY Installation

27. INSTALL FAN SHROUD Installation

28. INSTALL RADIATOR SUPPORT TO FRAME SEAL LH

29. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD)

30. INSTALL POWER STEERING LINK ASSEMBLY

Installation

31. INSTALL BATTERY

32. ADD ENGINE OIL Installation

33. ADD ENGINE COOLANT Service and Repair

34. ADD DIFFERENTIAL OIL (for 4WD)

35. INSPECT DIFFERENTIAL OIL (for 4WD) Adjustments

36. ADD POWER STEERING FLUID

37. BLEED POWER STEERING FLUID Power Steering System

38. CHECK FOR ENGINE OIL LEAKAGE

39. CHECK FOR ENGINE COOLANT LEAKAGE Service and Repair

40. CHECK FOR POWER STEERING FLUID LEAKAGE

41. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

Service and Repair

42. INSTALL V-BANK COVER Installation

43. INSPECT IGNITION TIMING Engine