Installation

1ZZ-FE ENGINE MECHANICAL: TIMING CHAIN:

COMPONENTS

INSTALLATION

1. INSTALL CHAIN SUB-ASSEMBLY
(a) Set the No. 1 cylinder to the TDC/compression.

(1) Turn the hexagonal wrench head portion of the camshafts until the point marks of the 2 camshaft timing gears are aligned.

(2) Using a crankshaft pulley bolt, turn the crankshaft to align the timing gear key with the point mark on the oil pump.

(b) Install the chain onto the crankshaft timing gear with the yellow mark link aligned with the timing mark on the crankshaft timing gear.

(d) Install the chain onto the camshaft timing gears with the yellow mark links aligned with the timing marks on the camshaft timing gears.
2. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the chain tensioner slipper with the bolt.
Torque: 18.5 Nm (189 kgf-cm, 14 ft-lbf)
3. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1

(a) Install the crankshaft position sensor plate with the "F" mark facing forward.
4. INSTALL TIMING CHAIN OR BELT COVER OIL SEAL
(a) Apply a light coat of multi-purpose grease to a new oil seal lip.

(b) Place the timing chain cover on wooden blocks.
(c) Using SST, tap the oil seal in until its surface is flush with the timing chain cover edge.
SST: 09223-22010

NOTE: Keep the lip free of foreign objects.

5. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
(a) Remove any old packing material from the contact surface.
(b) Apply a continuous bead of seal packing (Diameter 3.5 to 4.5 mm (0.138 to 0.177 in.)) as shown in the illustration.

Seal packing:
Water pump part
Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
Other part
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 start the engine for at least 2 hours after installing the chain cover.
- Be careful to only apply the specified thickness / volume of seal packing in area D.

(c) Install the timing chain cover with the 10 bolts and 2 nuts.
Bolt A and nut A - Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)
Bolt B - Torque: 18.5 Nm (189 kgf-cm, 14 ft-lbf)
(d) Using a "TORX" socket wrench (E8), install the stud bolt.
Torque: 9.5 Nm (97 kgf-cm, 84 in-lbf)
6. INSTALL CHAIN TENSIONER ASSEMBLY NO.1

(a) Check that the O-ring is clean, then set the hook as shown in the illustration.
(b) Apply a light coat of engine oil to the O-ring.

(c) Install the chain tensioner with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)

- Be careful not to twist the O-ring.
- When installing the chain tensioner, set the hook again if the hook releases the plunger.

7. INSTALL CRANKSHAFT PULLEY

(a) Align the pulley set key with the key groove of the crankshaft pulley, then slide on the crankshaft pulley.
(b) Using SST, install the crankshaft pulley bolt.
SST: 09960-10010
09962-01000
09963-01000
Torque: 138 Nm (1,407 kgf-cm, 102 ft-lbf)

(d) Turn the crankshaft clockwise, then check that the slipper is pushed by the plunger.
If the plunger is not extended, push the slipper into the chain tensioner using a screwdriver so that the hook is released from the knock pin and the plunger can be extended.
8. INSTALL CRANKSHAFT POSITION SENSOR
(a) Apply a light coat of engine oil to the O-ring of the crankshaft position sensor.
(b) Install the crankshaft position sensor with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
9. INSTALL WATER PUMP ASSEMBLY
(a) Install the water pump assembly (Installation).
10. INSTALL ENGINE MOUNTING BRACKET RH
Torque: 47 Nm (479 kgf-cm, 35 ft-lbf)
11. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

(a) Install the V-ribbed belt tensioner with the bolt and nut.
Bolt - Torque: 69 Nm (704 kgf-cm, 51 ft-lbf)
Nut - Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)
12. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Remove any old packing material from the contact surface.

(b) Apply seal packing to the 2 locations as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

- Remove any oil from the contact surface.
- Install the cylinder head cover within 3 minutes of applying seal packing.
- Do not put in engine oil for at least 2 hours after installation.

(c) Install the cylinder head cover and 3 clamp brackets with the 9 bolts, 2 seal washers and 2 nuts.
Bolt A and nut A - Torque: 11 Nm (112 kgf-cm, 8 ft-lbf)
Bolt B - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
(d) Install the 3 clamps of the engine wire onto the clamp bracket.
(e) Connect the ventilation hose No. 2.
(f) Connect the ventilation hose.
13. INSTALL IGNITION COIL ASSEMBLY
(a) Install the 4 ignition coils with the 4 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)

(b) Install the engine wire with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
(c) Connect the 4 ignition coil connectors.
14. 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 oil reservoir bracket No. 1 with the 2 bolts.
Torque: 7.8 Nm (80 kgf-cm, 69 in-lbf)
15. INSTALL GENERATOR ASSEMBLY
(a) Install the generator assembly (Installation).
16. INSTALL VANE PUMP ASSEMBLY
(a) Install the vane pump assembly (Installation).
17. INSTALL FAN AND GENERATOR V BELT
18. ADD ENGINE COOLANT
(a) Add the engine coolant (Testing and Inspection).
19. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
20. CHECK ENGINE COOLANT LEAK
(a) Check for the engine coolant leakage (Testing and Inspection).
21. CHECK ENGINE OIL LEAKAGE
22. INSTALL CYLINDER HEAD COVER NO.2
(a) Install the cylinder head cover No. 2 with the 2 nuts and 2 clips.
Torque: 7.0 Nm (71 kgf-cm, 62 in-lbf)
23. INSTALL FRONT WHEEL RH
Torque: 103 Nm (1,050 kgf-cm, 76 ft-lbf)