Timing chain installation (4JJ3 without DPD)

1) Rotate the crankshaft in the forward direction (clockwise) to align the No. 1 cylinder piston to compression top dead center.

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2) Install the timing chain guide to the cylinder head and cylinder block.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

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3) Insert the timing chain tension lever into the gap between the timing gear case and the cylinder block.

4) Align the timing chain with the supply pump sprocket.

5) Install the sprocket and timing chain as a set to idle gear D.

Tightening torque: 8.0 N・m { 0.8 kgf・m / 71 lb・in }

6) Apply engine oil to the threaded portion and seating surface of the idle gear D shaft bolt.

7) Install the idle gear D shaft bolt and sleeve to idle gear D and sprocket.

Tightening torque: 59 N・m { 6.0 kgf・m / 44 lb・ft }

8) Align the 2 timing alignment marks at the location shown in the diagram.

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9) Install the timing chain lever pivot to the timing chain tension lever.

Tightening torque: 27 N・m { 2.8 kgf・m / 20 lb・ft }

10) Push down the timing chain tensioner latch and insert the plunger.

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11) Install the timing chain tensioner and gasket to the cylinder head.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

12) Install the oil feed pipe to the timing chain tensioner.

Tightening torque: 14.7 N・m { 1.5 kgf・m / 130 lb・in }

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13) Lightly press the area indicated by the arrow in the diagram to disconnect the hook from the pin.

1) Referring to the diagram, apply ThreeBond 1207C or equivalent to the timing chain lower cover.

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Standard value

a: 2.0 to 2.5 mm { 0.079 to 0.098 in } Bead height

b: 2.0 to 2.5 mm { 0.079 to 0.098 in } Bead width

2) Install the timing chain lower cover to the gear case cover.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

3) Install the noise cover to the timing chain lower cover.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

1) Referring to the diagram, apply ThreeBond 1207C or equivalent to the timing chain upper cover.

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Standard value

a: 1.0 to 1.5 mm { 0.039 to 0.059 in } Bead height

b: 2.0 to 2.5 mm { 0.079 to 0.098 in } Bead width

2) Install the timing chain upper cover to the cylinder head.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

3) Connect the connector to the CMP sensor.

1) Install the tension pulley to the cylinder head.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

1) Install the water pipe to the following parts.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in } Bolt, nut

1) Install the A/C compressor drive belt to the following parts.

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Refer to "1.Engine 1B.Mechanical(4JJ3 without DPD) cylinder head cover installation".

1) Install the air cleaner to the vehicle.

Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }

2) Connect the connector to the MAF and IAT sensor.

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1) Align the air duct with the air cleaner and turbocharger.

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2) Referring to the diagram, align the alignment mark positions and connect the air duct to the turbocharger.

Tightening torque: 4.0 N・m { 0.4 kgf・m / 35 lb・in }

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3) Install the PCV hose to the cylinder head cover and air duct.

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4) Install the intake air duct to the air cleaner and radiator core support.

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Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard installation".

1. Post procedures

1) Lower the vehicle.

2) Connect the battery cable to the battery negative terminal.

3) Referring to the following, perform the setting of the front door power window switch with AUTO UP/AUTO DOWN function.

Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".

4) Close the engine hood.

1) Fill with engine coolant up to the radiator filler neck.

2) While pressing the radiator upper hose manually several times to bleed the air from the hose, fill the radiator with engine coolant.

3) Add engine coolant up to the MAX line of the radiator reserve tank.

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4) Install the radiator cap to the radiator.

5) Start and idle the engine.

6) Stop the engine.

7) Remove the radiator cap from the radiator.

8) Fill with engine coolant up to the radiator filler neck.

9) Install the radiator cap to the radiator.

10) Start the engine.

11) Increase the engine speed to around 2000 rpm and run the engine for 10 minutes once the engine coolant temperature gauge reaches the center.

12) With the engine running, check that the thermostat valve is open.

13) Idle the engine for 5 minutes.

14) Stop the engine.

15) Remove the radiator cap from the radiator.

16) Fill with engine coolant up to the radiator filler neck.

17) Add engine coolant up to the MAX line of the radiator reserve tank.

18) Install the radiator cap to the radiator.

19) Repeat steps 10 to 18 until the coolant level no longer lowers.

When installing a new belt, initial stretching of the belt occurs.
In addition, when reusing the belt, the belt needs to be fitted to the pulley groove.
After fitting the A/C compressor drive belt, adjust the tension of the A/C compressor drive belt again.

1) Loosen the tension pulley lock nut.

2) Turn the tension pulley adjust bolt to adjust the tension.

98 N { 10.0 kg / 22 lb } Load

Adjustment conditions	Deflection	Vibration frequency
When new	12.5 to 16.5 mm { 0.49 to 0.65 in }	92 to 112 Hz
Reused	16.5 to 19.1 mm { 0.65 to 0.75 in }	79 to 91 Hz

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3) Tighten the tension pulley lock nut to the specified torque.

Tightening torque: 51 N・m { 5.2 kgf・m / 38 lb・ft }