Timing Chain: Installation

1. Install the chain tensioner with the 2 bolts.

   Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

   Fig 1: Locating Chain Tensioner With Bolts

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2. While raising up the No. 2 chain tensioner, insert a pin of Ø 1.0 mm (0.039 in.) into the hole to fix it in place.

1. Align the No. 1 chain's orange mark plates with the camshaft timing gear's timing mark, and attach the chain to the gear as shown below.
   Fig 2: Aligning No. 1 Chain's Orange Mark Plate With Camshaft Timing Gear's Timing Mark (1 Of 2)

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2. Align the No. 1 chain's orange mark plate with the crankshaft timing gear's timing mark, and attach the chain to the gear as shown below.
   Fig 3: Aligning No. 1 Chain's Orange Mark Plate With Crankshaft Timing Gear's Timing Mark (2 Of 2)

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3. Align the No. 2 chain's mark plates (yellow) with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly, and attach the No. 2 chain to the gears as shown below.

   HINT:

   The crankshaft timing gear and camshaft exhaust gear assembly will be installed with the No. 1 and No. 2 chains connected to the gears.

   Fig 4: Aligning No. 2 Chain's Mark Plates (Yellow) With Timing Marks Of Camshaft Timing Gear

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4. Install the crankshaft timing gear to the crankshaft.
5. Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear assembly.
6. Using the hexagonal portion of the No. 2 camshaft, align and attach the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear assembly.
7. Remove the pin from the No. 2 chain tensioner.

1. Install the vibration damper with the 2 bolts.

   Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

   Fig 5: Locating Vibration Damper Bolts

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HINT:

If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain, and then install the chain tensioner slipper.

1. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
2. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.
   Fig 6: Pushing Plunger Deep Into Tensioner

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3. Install the chain tensioner with the 2 bolts.

   Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

   Fig 7: Locating Chain Tensioner & Bolts

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4. Remove the hexagon wrench from the chain tensioner.

1. Install the chain tensioner with the 2 bolts.

   Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

2. While pushing down the No. 2 chain tensioner, insert a pin of Ø 1.0 mm (0.039 in.) into the hole to fix it in place.
   Fig 8: Locating Chain Tensioner With Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Align the No. 1 chain's orange mark plates with the camshaft timing gear's timing mark, and attach the chain to the gear as shown below.
   Fig 9: Aligning No. 1 Chain's Orange Mark Plates With Camshaft Timing Gear's Timing Mark (1 Of 2)

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2. Align the No. 1 chain's orange mark plate with the crankshaft timing gear's timing mark, and attach the chain to the gear as shown below.
   Fig 10: Aligning No. 1 Chain's Orange Mark Plate With Crankshaft Timing Gear's Timing Mark (2 Of 2)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Align the No. 2 chain's mark plates (yellow) with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly, and attach the No. 2 chain to the gears as shown below.

   HINT:

   The crankshaft timing gear and camshaft exhaust gear assembly will be installed with the No. 1 and No. 2 chains connected to the gears.

   Fig 11: Aligning No. 2 Chain's Mark Plates (Yellow) With Timing Marks Of Camshaft Timing Gear Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the crankshaft timing gear to the crankshaft.
5. Align and attach the knock pin of the No. 3 camshaft with the pin hole of the camshaft timing gear assembly.
6. Using the hexagonal portion of the No. 4 camshaft, align and attach the knock pin of the No. 4 camshaft with the pin hole of the camshaft timing exhaust gear assembly.
   NOTE: Because the gears' timing mark positions may shift due to looseness of the No. 1 chain, use the hexagonal portion of the camshaft to hold the No. 3 camshaft in place until the No. 1 chain tensioner is installed.
7. Remove the pin from the No. 2 chain tensioner.

HINT:

If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain and install the chain tensioner.

1. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
2. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.
   Fig 12: Pushing Plunger Deep Into Tensioner

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the chain tensioner and gasket with the 2 bolts.

   Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

   Fig 13: Locating Chain Tensioner & Gasket With Bolts

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1. Install the vibration damper with the 2 bolts.

   Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

   Fig 14: Locating Chain Vibration Damper Bolts

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2. Remove the hexagon wrench from the No. 1 chain tensioner.

1. for Bank 1:
   1. Using a wrench, hold the hexagonal portion of the No. 3 camshaft.
   2. Using a 12 mm socket hexagon wrench, tighten the camshaft timing gear assembly with a new bolt.

      Torque: 79 N*m (806 kgf*cm, 58 ft.*lbf) 

      Fig 15: Holding Hexagonal Portion Of No. 3 Camshaft Using Wrench

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Using a wrench to hold the hexagonal portion of the No. 4 camshaft, tighten the camshaft timing exhaust gear assembly with the bolt.

      Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) 

      Fig 16: Holding Hexagonal Portion Of No. 4 Camshaft Using Wrench

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2. for Bank 2:
   1. Using a wrench, hold the hexagonal portion of the No. 1 camshaft.
   2. Using a 12 mm socket hexagon wrench, tighten the camshaft timing gear assembly with a new bolt.

      Torque: 79 N*m (806 kgf*cm, 58 ft.*lbf) 

      Fig 17: Holding Hexagonal Portion Of No. 1 Camshaft Using Wrench

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the camshaft timing exhaust gear assembly with the bolt.

      Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) 

1. Temporarily install the crankshaft pulley bolt.
2. Rotate the crankshaft clockwise, and check that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown below.
   Fig 18: Rotating Crankshaft Clockwise

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3. Remove the crankshaft pulley bolt.
   Fig 19: Identifying Timing Marks Position

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1. Install the timing chain cover (see REASSEMBLY  ).