Part 2

TIMING CHAIN Continued

3. INSTALL CHAIN SUB-ASSEMBLY
(a) Set the No. 1 cylinder to TDC/compression.
(1) Align the timing marks of the camshaft timing sprockets and bearing caps (No. 1 and No. 2).

(2) Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward.

(b) Align the mark link (gold or orange colored link) with timing mark of the crankshaft timing sprocket.

(d) Align the mark links (gold or yellow colored links) with the timing marks of the camshaft timing gear and camshaft timing sprocket. Install the chain.

4. INSTALL CHAIN TENSIONER SLIPPER
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)

5. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
6. INSTALL TIMING CHAIN OR BELT COVER SUBASSEMBLY

NOTICE:
^ Remove any oil from the contact surface.
^ Install the chain cover within 3 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing.

(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.
(b) Apply seal packing in a continuous bead (seal width: 2.0 mm (0.079 inch)) as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

(c) Apply seal packing in a continuous bead (seal width: 3.0 to 4.0 mm (0.12 to 0.16 inch)) as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

(d) Install the timing chain cover with the 14 bolts and 2 nuts.
Torque:
Bolt A
9.0 Nm (92 kgf-cm, 80 inch lbs.)
Bolt B
25 Nm (255 kgf-cm, 18 ft. lbs.)
Bolt C
55 Nm (561 kgf-cm, 41 ft. lbs.)
Nut
11 Nm (112 kgf-cm, 8 ft. lbs.)
(e) Install the stud bolt to the drive belt tensioner.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)

7. INSTALL CHAIN TENSIONER ASSEMBLY NO.1
8. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

9. INSTALL ENGINE MOUNTING BRACKET RH
(a) Install the engine mounting bracket RH with the 3 bolts.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)

10. INSTALL TRANSVERSE ENGINE MOUNTING INSULATOR
(a) Raise the engine and install the engine mounting insulator RH.
(b) Install the engine mounting insulator RH with the 4 nuts.
Torque: Bolt A
95 Nm (969 kgf-cm, 70 ft. lbs.)
Bolt B
87 Nm (887 kgf-cm, 64 ft. lbs.)

(d) Install the engine mounting insulator FR with the bolt.
Torque: 87 Nm (887 kgf-cm, 64 ft. lbs.)

11. INSTALL OIL PAN SUB-ASSEMBLY
12. INSTALL CRANKSHAFT POSITION SENSOR

13. INSTALL CRANKSHAFT PULLEY
(a) Install the crankshaft pulley.
(1) Align the pulley set key with the key groove of the pulley, and side on the pulley.
(2) Using SST, install the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021
Torque: 180 Nm (1,835 kgf-cm, 133 ft. lbs.)

HINT: Apply a light coat of engine oil to the bolt threads and the area beneath the bolt heads that come in contact with the washers.

14. INSTALL CHAIN TENSIONER ASSEMBLY NO.1
(a) Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out.

(b) Install a new gasket and the chain tensioner with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

NOTICE: If the hook is released while inserting, apply the hook again, and insert the chain tensioner.

(d) Turn the crankshaft clockwise and check that the slipper is pushed by the plunger.

15. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
16. INSTALL IGNITION COIL ASSEMBLY
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)

17. INSTALL VANE PUMP ASSEMBLY
18. INSTALL GENERATOR ASSEMBLY
19. INSTALL ENGINE WIRE
20. INSTALL FAN AND GENERATOR V BELT
21. INSTALL ENGINE MOUNTING BRACKET NO.2 RH
Torque: 52 Nm (531 kgf-cm, 38 ft. lbs.)

22. INSTALL ENGINE MOUNTING STAY NO.2 RH
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)

23. INSTALL ENGINE MOVING CONTROL ROD W/BRACKET
24. INSTALL EXHAUST PIPE ASSEMBLY FRONT
25. INSTALL FRONT WHEEL RH
26. INSTALL HOOD SUB-ASSEMBLY
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)

27. ADD ENGINE OIL
28. INSPECT FOR ENGINE OIL LEAK