Installation

2AZ-FE ENGINE MECHANICAL: TIMING CHAIN: INSTALLATION

TIMING CHAIN: INSTALLATION

1. INSTALL NO. 2 CHAIN SUB-ASSEMBLY

(a) Set the crankshaft key in the left horizontal position.
(b) Turn the cutout of the drive shaft to the top.

(c) Align the yellow mark links with the timing marks of the each gear as shown in the illustration.
(d) Install the gears onto the crankshaft and oil pump shaft with the chain wrapped on the gears.
(e) Temporarily tighten the oil pump drive shaft gear with the nut.

(f) Insert the damper spring into the adjusting hole, then install the chain tensioner plate with the bolt.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)

(g) Align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pump.
(h) Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, then tighten the nut.
Torque: 29.5 Nm (301 kgf-cm, 22 ft-lbf)

(i) Turn the crankshaft clockwise by 90° to position the crankshaft key upward.
2. INSTALL CRANKSHAFT TIMING SPROCKET
3. INSTALL NO. 1 CHAIN VIBRATION DAMPER
(a) Install the chain vibration damper with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
4. INSTALL CHAIN SUB-ASSEMBLY

(a) Set the No. 1 cylinder to TDC/compression.
(1) Turn the camshafts with a wrench in the hexagonal lobe to align the timing marks of the camshaft timing gear with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration.

(2) Using the crankshaft pulley bolt, turn the crankshaft to position the key on the crankshaft upward.

(b) Install the chain onto the crankshaft timing sprocket with the gold or orange mark link aligned with the timing mark on the crankshaft timing gear.

(d) Align the gold or yellow links with each timing mark located on the camshaft timing gear and sprocket, then install the chain.
5. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper with the bolt.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
6. INSTALL TIMING CHAIN GUIDE

(a) Install the timing chain guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
7. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

(a) Install the sensor plate with the "F" mark facing forward.
8. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
(a) Remove any old packing 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 of seal packing (Diameter 2.0 mm (0.079 in.)) as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE:
- Remove any oil from the contact surface.
- Install the chain cover within 3 minutes of applying seal packing.
- Do not add engine oil for at least 2 hours after installing the chain cover.

(c) Apply a continuous bead of seal packing as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE:
- Remove any oil from the contact surface.
- Install the chain cover within 3 minutes of applying seal packing.
- Do not add engine oil for at least 2 hours after installing the chain cover.

(d) Install the timing chain cover with the 14 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)
Torque: 55 Nm (561 kgf-cm, 41 ft-lbf)
Torque: 11 Nm (112 kgf-cm, 8 ft-lbf)
HINT: Bolt length:

(e) Using an E10 "TORX" socket, install the stud bolt for the V-ribbed belt tensioner.
Torque: 21.5 Nm (219 kgf-cm, 16 ft-lbf)
9. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Release the ratchet pawl, then fully push in the plunger and hook the hook to the pin so that the plunger is in the position shown in the illustration.

(b) Install a new gasket and the chain tensioner with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: When installing the chain tensioner, set the hook again if the hook releases the plunger.

10. INSTALL CRANKSHAFT PULLEY

(a) Using SST, fix the pulley in place and tighten the bolt.
SST: 09213-54015
91651-60855
SST: 09330-00021
Torque: 180 Nm (1,835 kgf-cm, 133 ft-lbf)

(b) Turn the crankshaft counterclockwise, then disconnect the plunger knock pin from the hook.

(d) Connect the wire harness protector clamp.
(e) Install the bolt.
Torque: 8.4 Nm (85 kgf-cm, 74 in-lbf)
11. INSTALL OIL PAN SUB-ASSEMBLY
(a) Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.

(b) Apply a continuous bead of seal packing (Diameter 3.0 to 4.0 mm (0.118 to 0.157 in.)) as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE:
- Remove any oil from the contact surface.
- Install the oil pan within 3 minutes of applying seal packing.
- Do not add engine oil for at least 2 hours after installing the oil pan.

(c) Install the oil pan to the cylinder block.

(d) Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)

(e) Place a transmission jack underneath the engine, then put a wooden block on the jack.
(f) Remove the chain block and sling device.
(g) Remove the No. 1 and No. 2 engine hangers.
12. INSTALL CRANKSHAFT POSITION SENSOR Installation
13. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

(a) Install the V-ribbed belt tensioner with the bolt and nut.
Torque: 59.5 Nm (607 kgf-cm, 44 ft-lbf)
NOTICE: Do not lift the engine more than necessary.

14. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Remove any old packing material from the contact surface.

(b) Apply seal packing to the 2 locations shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE:
- Remove any oil from the contact surface.
- Install the oil pan within 3 minutes of applying seal packing.
- Do not add engine oil for at least 2 hours after installing the oil pan.

(c) Install the cylinder head cover with the 8 bolts and 2 nuts.
Torque: 11 Nm (112 kgf-cm, 8 ft-lbf)
Torque: 14 Nm (143 kgf-cm, 10 ft-lbf)
Torque: 11 Nm (112 kgf-cm, 8 ft-lbf)

(d) Install the engine wire with the bolt (labeled A).
Torque: 8.4 Nm (86 kgf-cm, 74 in-lbf)
(e) Connect the clamp of the engine wire (labeled B).

(f) Connect the 2 ventilation hoses to the cylinder head cover.
15. INSTALL IGNITION COIL ASSEMBLY Installation
16. INSTALL ENGINE MOUNTING INSULATOR RH

(a) Install the engine mounting insulator RH with the 4 bolts and 2 nuts.
Torque: 52 Nm (530 kgf-cm, 38 ft-lbf)

(b) Install the front engine mounting insulator with the bolt and nut.
Torque: 52 Nm (530 kgf-cm, 38 ft-lbf)

(e) Install the No. 1 oil reservoir bracket with the 2 bolts.
Torque: 7.8 Nm (80 kgf-cm, 69 in-lbf)
(f) Install the return tube with the 2 bolts.
Torque: 7.8 Nm (80 kgf-cm, 69 in-lbf)

(g) Install the vane pump oil reservoir onto the No. 1 oil reservoir bracket.

(h) Install the radiator reservoir with the bolt.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
17. INSTALL VANE PUMP ASSEMBLY
18. INSTALL GENERATOR ASSEMBLY Installation
19. INSTALL FAN AND GENERATOR V BELT Installation
20. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation
21. ADD ENGINE OIL Replacement
22. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
23. INSPECT FOR OIL LEAK
24. INSPECT FOR EXHAUST GAS LEAK
25. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

(a) Install the engine cover with the 2 nuts.
Torque: 7.0 Nm (71 kgf-cm, 62 in-lbf)
26. INSTALL FRONT FENDER APRON SEAL RH
27. INSTALL ENGINE UNDER COVER LH
28. INSTALL ENGINE UNDER COVER RH
29. INSTALL FRONT WHEEL RH
30. INSTALL HOOD SUB-ASSEMBLY
31. PERFORM INITIALIZATION
(a) Perform initialization Testing and Inspection.
NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.