Installation

2UZ-FE ENGINE MECHANICAL: TIMING BELT: INSTALLATION

INSTALLATION

1. INSTALL NO. 2 TIMING BELT IDLER SUB-ASSEMBLY






(a) Install the idler with the bolt.
Torque: 35 Nm (352 kgf-cm, 25 ft-lbf)






2. INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY
(a) When reusing the timing belt idler shaft, apply adhesive to 2 or 3 of the threads.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(b) Using a 10 mm hexagon wrench, install the plate washer and idler with the bolt.
Torque: 35 Nm (352 kgf-cm, 25 ft-lbf)
3. INSTALL TIMING BELT
(a) Set the No. 1 cylinder to TDC/compression.





(1) Turn the hexagonal portion of the camshaft to align the timing marks of the camshaft timing pulleys and timing belt plates.





(2) Using the pulley set bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body.






(b) Install the timing belt.
(1) Remove any oil or water from each pulley, and keep them clean.
NOTE: Only wipe the pulleys. Do not use any cleansing agent on the pulleys.
(2) Face the front mark (arrow) on the timing belt forward.
(3) Align the timing marks on the timing belt and crankshaft timing pulley, and the timing belt and camshaft timing pulleys, and install the timing belt.
(c) Install the belt tensioner.





(1) Using a press, slowly press in the push rod using 981 to 9807 N (100 to 1000 kgf, 220.5 to 2204.7 lbf) of force.
(2) Align the holes of the push rod and housing, and pass a 1.5 mm hexagon wrench through the holes to keep the setting position of the push rod.
(3) Release the press.
(4) Install the dust boot to the belt tensioner.





(5) Temporarily install the belt tensioner with the 2 bolts.
(6) Tighten the 2 bolts.
Torque: 26 Nm (265 kgf-cm, 19 ft-lbf)
(7) Using pliers, remove the 1.5 mm hexagon wrench from the timing belt tensioner.
4. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION






(a) Using the pulley set bolt, slowly turn the crankshaft pulley 2 revolutions from the TDC to TDC.
NOTE: Always turn the crankshaft pulley clockwise.

(b) Check that each pulley is aligned with each timing mark as shown in the illustration.
If the timing marks are not aligned, remove the timing belt and reinstall it.
(c) Remove the pulley set bolt.
5. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE






(a) Install the sensor plate as shown in the illustration.
NOTE: Take care not to install it in a wrong direction.





6. INSTALL TIMING GEAR COVER SPACER
(a) Install the cover spacer and gasket.
7. INSTALL NO. 1 TIMING BELT COVER






(a) Install the cover spacer and gasket.
(b) Install the timing belt cover with the 4 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)






8. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY
(a) Align the pulley set key with the key groove of the crankshaft damper.
(b) Using SST, hold the crankshaft pulley and install the pulley bolt.
Torque: 245 Nm (2498 kgf-cm, 181 ft-lbf)
SST: 09213-70011
09213-70020
SST: 09330-00021
09330-00030






9. INSTALL FAN BRACKET SUB-ASSEMBLY
(a) Install the fan bracket with the 2 bolts and 2 nuts.
- for nut A, bolt B

Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)
- for nut C, bolt D

Torque: 32 Nm (326 kgf-cm, 24 ft-lbf)
10. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY






(a) Install the belt tensioner with the bolt and 2 nuts.
Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)
11. INSTALL NO. 2 TIMING BELT COVER SUB-ASSEMBLY






(a) Install the timing belt cover and fit the claws and pins into each part.
(b) Install the 2 bolts.
Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)
12. INSTALL NO. 3 TIMING BELT COVER SUB-ASSEMBLY LH






(a) Pass the camshaft position sensor wire through the cover hole.
(b) Install the cover with the 4 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
(c) Install the wire harness grommet to the belt cover.
(d) Connect the sensor connector.
(e) Install the sensor wire to the wire clamps on the cover.
(f) Connect the engine wire to the 4 wire clamps on the cover.
13. INSTALL NO. 2 TIMING CHAIN OR BELT COVER






(a) Install the cover with the 3 bolts and nut.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
14. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY






(a) Install the idler pulley and cover plate with the bolt.
Torque: 39 Nm (398 kgf-cm, 29 ft-lbf)
15. INSTALL OIL COOLER PIPE






(a) Connect the 3 water by-pass hoses.
(b) Install the oil cooler pipe with the cap nut and bolt.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
16. INSTALL COOLER COMPRESSOR ASSEMBLY






(a) Connect the compressor. Then install it and the No. 1 compressor stay with the nut and 3 bolts.
- for bolt

Torque: 47 Nm (479 kgf-cm, 35 ft-lbf)
- for nut

Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)
(b) Connect the connector.
17. INSTALL GENERATOR ASSEMBLY Installation

18. INSTALL VANE PUMP ASSEMBLY
(a) Install the vane pump assembly with 2 bolts.
Torque: 28 Nm (286 kgf-cm, 21 ft-lbf)
(b) Connect the connector.
19. INSTALL FAN SHROUD (w/ Trailer Towing System) Installation

20. INSTALL FAN SHROUD (w/o Trailer Towing System) Installation

21. INSTALL OUTLET RADIATOR HOSE Installation

22. INSTALL INLET RADIATOR HOSE Installation

23. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE Installation

24. INSTALL THROTTLE BODY COVER SUB-ASSEMBLY Installation

25. ADD ENGINE COOLANT Service and Repair

26. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

27. INSPECT FOR COOLANT LEAK Testing and Inspection

28. INSPECT IGNITION TIMING Engine

29. INSPECT ENGINE IDLE SPEED Engine

30. INSTALL NO. 1 ENGINE UNDER COVER Replacement