Note: Keep water or oil away from the camshaft and crankshaft pulleys and keep them clean.
1. Install the camshaft sprocket (if it was taken).
A) Align the dowel pin on the nose of the camshaft with the groove of the toothed pulley and fit the pulley onto the camshaft.
b) Temporarily install the pulley bolt.
V) Holding the camshaft by its hex part with an adjustable wrench, tighten the camshaft pulley bolt.
- Tightening torque - 59 Nm
2. Install the crankshaft sprocket (if it was taken).
A) Align the key on the crankshaft with the keyway on the toothed pulley.
b) Push the pulley onto the toe of the crankshaft until it stops with the flare inward.
3. Temporarily install the roller tensioner with spring.
A) Fasten the roller with the bolt without tightening it.
b) Install the spring.
V) Pull the roller to the left until it stops and tighten the bolt:
4. Install the timing belt.
Engine 5A-FE
A) Set the piston of the 1st cylinder to the BMI position at the end of the compression stroke.
With an adjustable wrench on the hex section of the camshaft, turn it and align the mark on the camshaft bearing cap with the center of the small hole on the camshaft pulley.
Using the crankshaft sprocket bolt, rotate the crankshaft and align the timing marks on the sprocket and on the oil pump housing.
b) Install the timing belt.
Warning: The engine must be cold.
Note: If the belt is to be reused, align the previously made marks on the pulleys and the belt and take into account the direction of rotation of the belt.
Install the timing belt, observing the marks and providing the necessary tension in the area between the toothed pulleys of the crankshaft and camshaft.
V) Check the correct installation of the belt (valve timing).
Slowly loosen the idler pulley bolt.
Slowly turn the crankshaft 2 turns clockwise from TDC to TDC after installing the toothed pulley mounting bolt.
Make sure the timing marks on each pulley match up with the timing marks on the oil pump housing (for crankshaft pulley) and on the camshaft bearing cap as shown.
Tighten the tensioner pulley bolt.
- Tightening torque - 38 Nm
G) Install the toothed belt guide with the flare outwards as shown in the illustration.
d) Install protective cover #1.
- Bolt tightening torque - 8 Nm
Engine 4A-FE
A) Set the piston of the 1st cylinder to the TDC position at the end of the compression stroke.
With an adjustable wrench on the hex section of the camshaft, turn it and align the mark on the camshaft bearing cap with the center of the small hole on the camshaft pulley.
Temporarily install the timing belt.
Install the timing belt guide facing out.
Install timing belt cover #1.
- Tightening torque - 8 Nm
Install the crankshaft pulley.
Rotate the crankshaft pulley and align it with the alignment mark "ABOUT" on cover #1 of the timing belt.
b) Install the timing belt.
Warning: The engine must be cold.
Note: If the belt is to be reused, align the previously made marks on the pulleys and the belt and take into account the direction of rotation of the belt.
Install the timing belt, observing the marks and providing the necessary tension in the area between the toothed pulleys of the crankshaft and camshaft.
Check the correct installation of the belt (valve timing).
Slowly loosen the idler pulley bolt.
Slowly turn the crankshaft 2 turns clockwise from TDC to TDC after installing the toothed pulley mounting bolt.
Make sure the timing marks on each pulley align with their respective timing marks as shown.
Tighten the tensioner pulley bolt.
- Tightening torque - 38 Nm
5. Install the right engine mount by tightening the 3 bolts and 3 fastening nuts.
Torque:
- nut - 53 Nm
- bolt - 74 Nm
6. Lower the engine with a hoist.
7. Install the crankshaft pulley.
A) Align the key on the crankshaft with the pulley groove and fit the pulley onto the shaft.
b) Using a suitable tool, install and tighten the crankshaft pulley mounting bolt.
- Tightening torque - 120 Nm
8. Install the water pump pulley.
9. Establish an arm of the compressor of the conditioner, having wrapped 4 bolts of fastening.
- Tightening torque - 48 Nm
10. Install the air conditioning compressor by tightening the 4 mounting bolts.
- Tightening torque - 25 Nm
11. (4A-FE, 7A-FE) Install the pressure sensor wire in the combustion chamber,
12. Install timing belt cover #3.
- Tightening torque - 8 Nm
13. Establish a cover of a head of the block of cylinders.
A) Remove old sealant.
b) Apply a layer of fresh sealant in the areas shown in the illustration.
V) Install the gasket under the cylinder head cover.
G) Install the block head cover, securing it with 4 nuts installed on the sealing washers.
- Tightening torque of nuts - 6 Nm
14. Connect the crankcase ventilation hoses.
15. Connect high voltage wires.
16. Connect the wiring harness and install the wire harness guard.
17. Install the power steering pump drive belt.
18. Install the A/C compressor drive belt.
19. Install the washer reservoir.
20. Install the alternator drive belt.
21. Tighten the coolant pump pulley bolts.
- Tightening torque - 10 Nm
22. Install the right side of the engine protection.
23. Connect the negative plug to the storage battery.