Timing Belt: Installation

WARNING: This page is about a different car, the 2007 Lexus GS 430. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL TIMING BELT
1. Check the No. 1 and No. 2 belt idlers.
  1. Visually check the seal portion of the idler pulley for oil leakage.
    If leakage is found, replace the idler.
  2. Check that the idler turns smoothly.
    If necessary, replace the idler.
2. Check the water pump.
  1. Visually check the air hole and water hole for coolant leakage.
    If leakage is found, replace the water pump and belt.
  2. Turn the pulley, and check that the water pump bearing moves smoothly and quietly.
    If necessary, replace the water pump.
3. Remove any oil or water on the crankshaft, oil pump pulley, water pump pulley, No. 1 and No. 2 idler. Keep them clean.
  NOTE: Only wipe the pulleys. Do not use any cleansing agents on the pulleys.
  
  Fig 1: Identifying Air Hole And Drain Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Set the No. 1 cylinder to TDC/compression.
  1. Turn the hexagon head portion of the camshaft to align the timing marks of the camshaft timing pulleys and timing belt plates.
    
    Fig 2: Identifying Timing Marks Of Camshaft Timing Pulleys And Timing Belt Plates
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    HINT:
    
    Turn the camshaft timing pulleys slightly clockwise to make installation of the timing belt easier.
    
    Camshaft timing pulley of LH bank:
    
    1/2 of a tooth
    
    Camshaft timing pulley of RH bank:
    
    1 tooth
    
    Fig 3: Identifying Make On Timing Belt
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body.
    
    Fig 4: Turning Crankshaft Of Crankshaft Timing Pulley And Oil Pump Body
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Remove any oil or water on each pullet. Keep them clean.
    NOTE: Only wipe the pulleys. Do not use cleaning agents on the pulleys.
  4. Face the front mark (arrow) on the belt forward.
  5. Connect the belt to the crankshaft timing pulley. Align the installation mark on the belt with the timing mark of the crankshaft timing pulley.
  6. Connect the belt to the No. 2 idler.
  7. Connect the belt to the camshaft timing pulley (LH bank). Align the installation mark on the belt with the timing mark of the camshaft timing pulley.
  8. Connect the belt to the water pump pulley.
  9. Connect the belt to the camshaft timing pulley (RH bank). Align the installation mark on the belt with the timing mark of the camshaft timing pulley.
  10. Connect the timing belt to the No. 1 idler.
  Fig 5: Identifying Timing Mark Of Crankshaft Timing Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Set the belt tensioner.
  1. Using a press, slowly press in the push rod using 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) of pressure.
  2. Align the holes of the push rod and housing. Pass a 1.27 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.
  Fig 6: Aligning Holes Of Push Rod And Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the belt tensioner.
  1. Temporarily install the belt tensioner with the 2 bolts.
  2. Alternately tighten the 2 bolts.
    Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)
  3. Using pliers, remove the 1.27 mm hexagon wrench from the belt tensioner.
  Fig 7: Locating Belt Tensioner With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Check the valve timing.
  1. Using the crankshaft damper bolt, slowly turn the crankshaft timing pulley 2 revolutions from TDC to TDC.
    NOTE: Always turn the crankshaft pulley clockwise.
    
    Fig 8: Turning Crankshaft Pulley
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Check that each pulley aligns with the timing marks as shown in the illustration.
    If the pulley and timing marks do not align, remove the belt and reinstall it.
  3. Remove the crankshaft damper bolt.
Fig 9: Identifying Timing Marks On Pulley
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE
1. Install the sensor plate as shown in the illustration.
  
  Fig 10: Identifying Sensor Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful of the installation direction.
INSTALL NO. 1 TIMING BELT COVER
1. Install the timing belt cover with the 4 bolts.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY
1. Align the damper set key with the key groove of the crankshaft damper.
2. Using SST and a hammer, tap in the damper.
  SST 09223-46011
  
  Fig 11: Aligning Damper Set Key With Key Groove Of Crankshaft Damper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, install the damper bolt.
  SST 09213-70011, 09330-00021
  
  Torque: 245 N*m (2,498 kgf*cm, 181 ft.*lbf)
Fig 12: Tightening Damper Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY
1. Install the idler with the 2 bolts and 2 nuts.
  Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) for 12 mm head
  
  Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) for 14 mm head
  
  Bolt length:
  
  106 mm (4.17 in.) for 12 mm head bolt A
  
  114 mm (4.49 in.) for 14 mm head bolt B
Fig 13: Tightening Idler Pulley With Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
1. Install the belt tensioner with the bolt and 2 nuts.
  Torque: 15.5 N*m (158 kgf*cm, 11 ft.*lbf)
  
  HINT:
  
  Use a bolt that is 106 mm (4.17 in.) in length.
Fig 14: Locating Belt Tensioner Bolt And Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 TIMING BELT COVER SUB-ASSEMBLY
1. Set the No. 2 cover by matching the claws and pin with each part.
2. Install the timing belt cover with the 2 bolts.
  Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
  
  HINT:
  
  Use bolts that are 106 mm (4.17 in.) in length.
Fig 15: Locating Timing Belt Cover And Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
1. Install the idler pulley and cover plate with the bolt.
Fig 16: Locating Idler Pulley Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 3 TIMING BELT COVER SUB-ASSEMBLY LH
1. Install the gasket to the cover.
2. Pass the camshaft position sensor wire through the cover hole.
3. Install the cover with the 4 bolts.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
4. Install the wire grommet to the cover.
5. Install the sensor connector to the sensor holder.
6. Connect the sensor connector.
7. Install the sensor wire to the wire clamp on the cover.
8. Install the engine wire to the 2 wire clamps on the cover.
  
  Fig 17: Locating Timing Belt Cover With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Connect the 2 water bypass hoses as shown in the illustration.
10. Install the No. 3 water bypass pipe to the cover with the cap nut.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
Fig 18: Locating Water Bypass Hoses
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 3 TIMING BELT COVER SUB-ASSEMBLY RH
1. Install the gasket to the cover.
2. Install the cover with the cap nut and 3 bolts.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
Fig 19: Locating No. 3 Timing Belt Cover With Cap Nut And Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT COMPRESSOR WITH PULLEY ASSEMBLY
1. Set the cooler compressor to the engine. Then install the stay, wire bracket, 3 bolts and nut to connect the cooler compressor.
  Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) for bolts
  
  29 N*m (295 kgf*cm, 21 ft.*lbf) for nuts
Fig 20: Identifying Compressor With Pulley Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 IDLER PULLEY BRACKET SUB-ASSEMBLY
1. Install the bracket with the 2 bolts.
  Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
  
  Fig 21: Locating Bracket Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the idler pulley and pulley plate with the bolt.
  
  Fig 22: Locating Idler Pulley Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
INSTALL GENERATOR ASSEMBLY (See INSTALLATION )
INSTALL FAN AND GENERATOR V-BELT (See INSTALLATION )
INSTALL RADIATOR ASSEMBLY
1. Install the radiator (see INSTALLATION ).
CONNECT NO. 1 OIL COOLER OUTLET TUBE (See INSTALLATION )
CONNECT NO. 1 OIL COOLER INLET TUBE (See INSTALLATION )
CONNECT RADIATOR HOSE OUTLET (See INSTALLATION )
CONNECT RADIATOR HOSE INLET
INSTALL AIR CLEANER ASSEMBLY
1. Install the air cleaner assembly with the 3 bolts.
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
2. Connect the MAF meter connector and clamp to the air cleaner.
INSTALL NO. 1 AIR CLEANER INLET
1. Install the No. 1 air cleaner inlet and bolt.
  
  Fig 23: Locating Air Cleaner Assembly With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
INSTALL INTAKE AIR CONNECTOR PIPE (See INSTALLATION )
INSTALL V-BANK COVER
1. Install the V-bank cover with the 2 nuts.
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
REMOVE ENGINE ROOM SIDE COVER LH (See INSTALLATION )
REMOVE ENGINE ROOM SIDE COVER RH (See INSTALLATION )
REMOVE COOL AIR INTAKE DUCT SEAL (See INSTALLATION )
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
PERFORM INITIALIZATION
1. Perform initialization (see INITIALIZATION ).
  NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
ADD ENGINE COOLANT (See COOLANT )
CHECK FOR ENGINE COOLANT LEAKS
1. Check for engine coolant leaks (see COOLING SYSTEM ).
INSTALL ENGINE UNDER COVER