Contents: Removal the power steering pump…↓ Removal the right engine mount…↓ Removal the crankshaft pulley ↓ Removal the support roller assembly ↓ Disconnecting the engine wiring…↓ Removal timing belt drive cover No.2 ↓ Removal timing belt drive cover No.1 ↓ Removal the transverse engine…↓ Setting the piston of cylinder No.1…↓ Removal the timing chain cover plate ↓ Removal the timing belt drive ↓ Setting the piston of cylinder No.1…↓ Installing the timing belt drive ↓ Checking the valve timing ↓ Installing the timing belt drive…↓ Installing timing belt drive cover…↓ Installing timing belt drive cover…↓
Fig. 2.337. Timing belt drive components
Disconnect the negative battery terminal.
Remove the front right wheel.
Remove the lower shield of engine No.1.
Remove the lower right engine shield.
Remove the upper radiator shroud.
Remove engine cover No.1.
Remove the injector drive electronic unit.
Remove V-belt No.1 (air conditioning compressor drive from crankshaft pulley).
Remove the alternator drive V-belt.
Removal the power steering pump support roller bracket
Fig. 2.338. Bolts for fastening the bracket of the support roller of the power steering pump
Remove 3 bolts and power steering pump support roller bracket (fig. 2.338).
Note: Do not remove the hoses, but secure them to the body.
Removal the right engine mount cushion
Fig. 2.339. Installing the jack
Place a jack under the engine, using a wooden block as a support (fig. 2.339).
Remove the bolt, then disconnect the fuel return line.
Remove 3 bolts and 3 nuts, then remove the right engine mount cushion.
Removal the crankshaft pulley
Using SST, remove the pulley mounting bolt.
Fig. 2.340. Installing a special tool
Note: When using SST(A) (09213-70020) a flat washer (5mm) should be inserted between SST(A) and SST(B) (fig. 2.340).
Fig. 2.341. Removing the crankshaft pulley
Using SST remove the pulley (fig. 2.341).
Removal the support roller assembly
Fig. 2.342. Support roller pulley mounting bolt
Remove the bolt and washer, then remove the pulley (fig. 2.342).
Disconnecting the engine wiring harness
Fig. 2.343. Fastening the engine wiring harness
Remove 2 bolts and nut, then disconnect 3 wire harness clamps (fig. 2.343).
Removal timing belt drive cover No.2
Fig. 2.344. Fastening cover No.2 of the timing belt drive
Remove 7 bolts, 7 sealing washers, then remove the timing belt cover (fig. 2.344).
Removal timing belt drive cover No.1
Fig. 2.345. Fastening the engine wiring harness
Remove 5 bolts, 5 sealing washers, then remove the timing belt cover (fig. 2.345).
Remove the timing belt drive support roller.
Removal the transverse engine support bracket
Fig. 2.346. Fastening the support bracket of a transversely mounted engine
Remove 4 bolts and engine mount bracket (fig. 2.346).
Setting the piston of cylinder No.1 to TDC of the compression stroke
Fig. 2.347. Alignment of the mark on the timing gear with the TDC mark of the oil pump
Turn the crankshaft by the crankshaft pulley mounting bolt and align the mark on the timing gear with the TDC mark on the oil pump (fig. 2.347).
Fig. 2.348. Alignment of the mark on the camshaft drive pulley with the parting line of the cylinder head and cylinder head cover
Make sure that the timing mark on the camshaft drive pulley is aligned with the parting line of the cylinder head and cylinder head cover (fig. 2.348).
Removal the timing chain cover plate
Fig. 2.349. Timing chain drive cover plate mounting bolt
Remove the bolt and timing chain cover plate (fig. 2.349).
Removal the timing belt drive
Fig. 2.351. Timing belt tensioner mounting bolts
Gradually loosen the 2 bolts alternately to remove the timing belt tensioner (fig. 2.351).
Remove the timing belt drive.
Fig. 2.350. Timing belt drive marks
Note: If the timing belt drive is to be reused, mark the belt with an arrow indicating the direction of rotation of the engine crankshaft and mark the pulleys and belt with alignment marks before removing the belt. This will help when reinstalling the timing belt drive (fig. 2.350).
Setting the piston of cylinder No.1 to TDC of the compression stroke
Fig. 2.352. Alignment of pulley marks with the synchronizing mark on the cylinder head and on the coolant pump
Using SST, install the crankshaft pulleys and fuel injection pump so that the pulley marks are aligned with the timing mark on the cylinder head and on the water pump (fig. 2.352).
Turn the crankshaft by the crankshaft pulley mounting bolt and align the mark on the timing gear with the TDC mark on the oil pump (fig. 2.347).
Note: Be careful when rotating the camshaft and crankshaft, as the valve heads may come into contact with the piston crowns. This contact may cause the valve heads to bend.
Installing the timing belt drive
Remove any remaining oil and water from the pulleys, then clean the pulleys.
Note: Perform work on a cold engine.
Note: The use of chemical cleaning agents is prohibited.
Fig. 2.353. Timing belt drive components installation order: 1 – camshaft drive gear; 2 – fuel pump drive gear; 3 – coolant pump pulley; 4 – Timing drive gear (crankshaft gear); 5 – support roller No.2; 6 – leading gear of the oil pump; 7 – support roller No.1
Install the timing belt drive in the following order shown in Figure 2.353.
Fig. 2.354. Combination of synchronization marks
Make sure the timing marks are aligned as shown in Figure 2.354.
Install the belt tensioner.
Using a press, carefully press the tensioner rod with a force of 981–9807 N.
Fig. 2.355. Fixing the tensioner rod in the installation position using a hex key
Align the holes in the rod and the housing, then insert a hex key (1.27 mm) into the holes to lock the tensioner rod in the installation position (fig. 2.355).
Remove the tensioner from under the press.
Install the tensioner by loosely tightening the mounting bolt (A).
Fig. 2.356. Turning the tensioner before installing the second mounting bolt
Turn the tensioner clockwise, then tighten the second mounting bolt (fig. 2.356).
Gradually tighten the 2 bolts alternately.
Tightening torque: 21 Nm.
Fig. 2.357. Removing the hexagon
Remove the hex key from the tensioner (fig. 2.357).
Checking the valve timing
Fig. 2.358. Turning the crankshaft 2 full revolutions
(The original can be found on this resource ToyotaMAN)
Slowly rotate the crankshaft 2 full turns (720°) from TDC to TDC (fig. 2.358).
Note: Rotate the crankshaft clockwise only.
Attention! Align the TDC mark with the dot mark.
Fig. 2.359. Alignment of synchronizing marks on pulleys with marks on the engine
Make sure that the timing marks on the pulleys are aligned with the marks on the engine, as shown in Figure 2.359.
If the marks do not align, remove the timing belt drive and reinstall it.
Remove the crankshaft pulley mounting bolt.
Install the timing chain cover plate.
Tightening torque: 9.0 Nm.
Fig. 2.360. The order of loosening and tightening the bolts for fastening the support bracket of a transversely mounted engine
Install the transverse engine support bracket and loosely tighten the 6 bolts (fig. 2.360).
Tighten 4 bolts A to the specified torque.
Tightening torque: 37 Nm for bolt A.
Remove 2 bolts B.
Installing the timing belt drive support roller
Fig. 2.361. Installation diagram of the belt drive support roller
Install the belt drive support roller with the cover facing outward (fig. 2.361).
Installing timing belt drive cover No.1
Make sure the timing belt cover gasket is not cracked, deformed, etc.
If the gasket is cracked or deformed, replace it by following the steps below.
Use a screwdriver and scraper to remove any remaining old gasket.
Thoroughly clean all parts from any remaining sealant.
Fig. 2.362. Diagram of installation of a new gasket on cover No.1 of the timing belt drive
Remove the protective paper from the new gasket, then secure the gasket to the timing belt drive cover as shown in Figure 2.362.
Note: Place the gasket evenly in the groove.
At the corners the thickness of the gasket should not decrease.
Then press firmly on the gasket so that it is securely bonded to the timing belt cover.
If a gap forms between the ends of the gasket, fill it with sealant.
Secure the timing belt cover with gasket using 5 bolts and 5 sealing washers.
Tightening torque: 7.4 Nm.
After installing the timing belt cover, make sure that the gasket is not warped or squeezed out from under the cover.
Installing timing belt drive cover No.2
Make sure the timing belt cover gasket is not cracked, deformed, etc.
If the gasket is cracked or deformed, replace it by following the steps below.
Use a screwdriver and scraper to remove any remaining old gasket.
Thoroughly clean all parts from any remaining sealant.
Fig. 2.363. Diagram of installation of a new gasket on cover No.1 of the timing belt drive
Remove the protective paper from the new gasket, then secure the gasket to the timing belt drive cover as shown in Figure 2.363.
Note: Place the gasket evenly in the groove.
Note: The thickness of the gasket should not decrease at the corners.
Then press firmly on the gasket so that it is securely bonded to the timing belt cover.
If a gap forms between the ends of the gasket, fill it with sealant.
Secure the timing belt cover with gasket using 7 bolts and 7 sealing washers.
Tightening torque: 7.4 Nm.
After installing the timing belt cover, make sure that the gasket is not warped or squeezed out from under the cover.
Note: Install the remaining components in the reverse order of removal.