Timing Chain: Installation

WARNING: This page is about a different car, the 2008 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL NO. 2 CHAIN SUB-ASSEMBLY
1. Set the crankshaft key in the left horizontal position.
2. Turn the cutout of the drive shaft so that it faces upward.
  
  Fig 1: Turning Cutout Of Drive Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Align the yellow mark links with the timing marks of each gear as shown in the illustration.
  
  Fig 2: Aligning Links With Timing Marks Of Each Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the sprockets onto the crankshaft and oil pump shaft with the chain wrapped on the gears.
5. Temporarily tighten the oil pump drive shaft sprocket with the nut.
6. Insert the damper spring into the adjusting hole, and then install the chain tensioner plate with the bolt.
  Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
  
  Fig 3: Identifying Chain Tensioner Plate With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Align the adjusting hole of the oil pump drive shaft sprocket with the groove of the oil pump.
8. Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, and then tighten the nut.
  Torque: 29.5 N*m (301 kgf*cm, 22 ft.*lbf)
  
  Fig 4: Identifying 4 mm Diameter Bar Into Adjusting Hole Of Oil Pump Drive Shaft Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT TIMING SPROCKET

Fig 5: Identifying Crankshaft Timing Sprocket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 CHAIN VIBRATION DAMPER
1. Install the chain vibration damper with the 2 bolts.
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
  
  Fig 6: Identifying Chain Vibration Damper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CHAIN SUB-ASSEMBLY
1. Set the No. 1 cylinder to TDC/compression.
  1. Turn the camshafts with a wrench (using 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.
    
    Fig 7: Aligning Timing Marks Of Camshaft Timing Gear
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Using the crankshaft pulley bolt, turn the crankshaft to position the key on the crankshaft upward.
    
    Fig 8: Turning Crankshaft To Position Key On Crankshaft Upward
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the chain onto the crankshaft timing sprocket with the gold or orange mark link aligned with the timing mark on the crankshaft.
  
  Fig 9: Aligning With Timing Mark On Crankshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a hammer, tap in the crankshaft timing sprocket.
  SST 09309-37010
  
  Fig 10: Tapping In Crankshaft Timing Sprocket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Align the gold or yellow links with each timing mark located on the camshaft timing gear and sprocket, then install the chain.
  
  Fig 11: Identifying Mark Link And Timing Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CHAIN TENSIONER SLIPPER
1. Install the chain tensioner slipper with the bolt.
  Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
  
  Fig 12: Identifying Chain Tensioner Slipper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TIMING CHAIN GUIDE
1. Install the timing chain guide with the bolt.
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
  
  Fig 13: Identifying Timing Chain Guide
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE
1. Install the sensor plate with the "F" mark facing forward.
  
  Fig 14: Identifying Crankshaft Position Sensor Plate Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

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.
Apply seal packing (Diameter 4.0 to 4.5 mm (0.157 to 0.177 in.)) as shown in the figure below.
Seal packing: Toyota Genuine Seal Packing Block, Three Bond 1207B or Equivalent
NOTE:
- 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.
Fig 15: Identifying Seal Packing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Apply a continuous bead of seal packing as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Block, Three Bond 1207B or Equivalent
NOTE:
- 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.
Fig 16: Identifying Chain Cover With Specifications
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the timing chain cover with the 12 bolts and 2 nuts.

Torque:

9.0 N*m (92 kgf*cm, 80 in.*lbf) for bolt A

25 N*m (255 kgf*cm, 18 ft.*lbf) for bolt B

55 N*m (561 kgf*cm, 41 ft.*lbf) for bolt C

11 N*m (112 kgf*cm, 8 ft.*lbf) for nut

HINT:

Bolt length:

BOLT LENGTH REFERENCE

Bolt A	30 mm (1.18 in.) length for 10 mm head
Bolt B	30 mm (1.18 in.) length for 12 mm head
Bolt C	40 mm (1.57 in.) length for 14 mm head

Fig 17: Identifying Timing Chain Cover With Bolts

Using an E10 "Torx" socket, install the stud bolt for the V-ribbed belt tensioner.
Torque: 21.5 N*m (219 kgf*cm, 16 ft.*lbf)

Fig 18: Installing Stud Bolt For V-Ribbed Belt Tensioner
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
1. 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.
  
  Fig 19: Pushing Plunger Hook To Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install a new gasket and the chain tensioner with the 2 nuts.
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
  
  NOTE: When installing the chain tensioner, set the hook again if the hook releases the plunger.
  
  Fig 20: Identifying Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
1. Install the V-ribbed belt tensioner with the bolt and nut.
  Torque: 59.5 N*m (607 kgf*cm, 44 ft.*lbf)
  
  NOTE: Do not lift the engine more than necessary.
  
  Fig 21: Identifying V-Ribbed Belt Tensioner Bolt And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE MOUNTING BRACKET RH
1. Install the engine mounting bracket RH with the 3 bolts.
  Torque: 55 N*m (561 kgf*cm, 41 ft.*lbf)
  
  Fig 22: Identifying Engine Mounting Bracket Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT PULLEY
1. Using SST, fix the pulley in place and tighten the bolt.
  SST 09213-54015 (91651-60855), 09330-00021
  
  Torque: 180 N*m (1,835 kgf*cm, 133 ft.*lbf)
  
  Fig 23: Identifying Crankshaft Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Turn the crankshaft counterclockwise, then disconnect the plunger knock pin from the hook.
  
  Fig 24: Turning Crankshaft Counterclockwise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Turn the crankshaft clockwise, then check that the plunger is extended.
Fig 25: Turning Crankshaft Clockwise
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL PAN SUB-ASSEMBLY
1. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.
2. 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 Block, Three Bond 1207B or Equivalent
  
  Fig 26: Applying Continuous Bead Of Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - 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.
3. Install the oil pan to the cylinder block.
4. Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration.
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
  
  Fig 27: Tightening Oil Pan Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Place a transmission jack underneath the engine, then put a wooden block on the jack.
6. Remove the chain block and sling device.
7. Remove the No. 1 and No. 2 engine hangers.
INSTALL CRANKSHAFT POSITION SENSOR (see appropriate step(s) under INSTALLATION )
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
1. Remove any old packing material from the contact surface.
  
  Fig 28: Putting Wooden Block On Jack
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply seal packing to the 2 locations shown in the illustration.
  Seal packing: Toyota Genuine Seal Packing Block, Three Bond 1207B or Equivalent
  
  Fig 29: Applying Seal Packing To Locations
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - 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.
3. Install the cylinder head cover with the 8 bolts and 2 nuts.
  Torque:
  
  11 N*m (112 kgf*cm, 8 ft.*lbf) for bolt A
  
  14 N*m (143 kgf*cm, 10 ft.*lbf) for bolt B
  
  11 N*m (112 kgf*cm, 8 ft.*lbf) for nut
  
  Fig 30: Identifying Cylinder Head Cover With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 2 engine wires with the 2 bolts.
  Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)
  
  Fig 31: Identifying Engine Wire Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the 2 ventilation hoses to the cylinder head cover.
  
  Fig 32: Identifying Ventilation Hoses From Cylinder Head Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SPARK PLUG (see appropriate step(s) under ADJUSTMENT )
INSTALL IGNITION COIL ASSEMBLY (see INSTALLATION )
INSTALL IDLER PULLEY
1. Install the idler pulley with the 2 bolts.
  Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf)
  
  Fig 33: Identifying Idler Pulley Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE MOUNTING INSULATOR RH
1. Install the engine mounting insulator RH with the 4 bolts and 2 nuts.
  Torque:
  
  95 N*m (969 kgf*cm, 70 ft.*lbf) for bolt
  
  95 N*m (969 kgf*cm, 70 ft.*lbf) for nut A
  
  52 N*m (530 kgf*cm, 38 ft.*lbf) for nut B
  
  Fig 34: Identifying Engine Mounting Insulator RH Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the 2 clamps of the engine wire.
  
  Fig 35: Identifying Clamps Of Engine Wire
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the wire harness protector with the bolt.
INSTALL ENGINE MOUNTING INSULATOR FR
1. Install the engine mounting insulator FR with the 2 bolts.
  Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
  
  Fig 36: Identifying Engine Mounting Insulator FR
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the through bolt and nut.
  Torque: 145 N*m (1,479 kgf*cm, 107 ft.*lbf)
  
  HINT:
  
  Install the bolt which is used to secure the front engine mounting bracket FR.
  
  Fig 37: Identifying Through Bolt And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RADIATOR RESERVOIR
1. Install the radiator reservoir with the 2 bolts.
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
  
  Fig 38: Identifying Radiator Reservoir Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR ASSEMBLY (see INSTALLATION )
INSTALL FAN AND GENERATOR V BELT (see appropriate step(s) under INSTALLATION )
INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH (see appropriate step(s) under INSTALLATION )
INSTALL FRONT EXHAUST PIPE (see INSTALLATION )
ADD ENGINE OIL (see appropriate step(s) under REPLACEMENT )
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
CHECK FOR ENGINE OIL LEAKS
CHECK FOR EXHAUST GAS LEAKS
INSTALL NO. 1 ENGINE COVER
1. Install the engine cover with the 2 nuts.
  Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)
  
  Fig 39: Identifying Engine Cover Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT FENDER APRON RH
INSTALL NO. 1 ENGINE UNDER COVER
INSTALL FRONT WHEEL RH
INSTALL RADIATOR SUPPORT OPENING COVER