Installation
1NZ-FXE ENGINE MECHANICAL: TIMING CHAIN: INSTALLATION
INSTALLATION
1. INSTALL CHAIN
(a) Set the position of the No. 1 cylinder to 20° ATDC.
NOTE: To prevent the pistons from hitting against valves, the following procedures must be performed in the order below.
(1) Set the crankshaft between 40 to 140° ATDC.
(2) Set the cams of the intake and exhaust timing sprockets to 20° ATDC.
(3) Reset the crankshaft to 20° ATDC.
(b) Install the chain vibration damper with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
(c) Align the timing marks of the camshaft timing sprocket, camshaft timing gear and crankshaft timing sprocket with each mark plate (colored in yellow) of the timing chain.
HINT: To prevent the exhaust camshaft from springing back, turn it using a wrench and set it at the mark on the chain.
(d) Install the chain tensioner slipper with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
(e) Install the chain tensioner with the 2 bolts.
(1) Lift up the stopper plate, then unlock the plunger.
(2) Push in the plunger to the end with the plunger unlocked.
(3) Lower the stopper plate with the plunger pushed to the end, then lock the plunger.
(4) Insert a 3.0 mm (0.118 in.) diameter bar into the hole of the stopper plate with the plunger locked.
HINT: If the stopper plate is not completely lowered and a 3.0 mm (0.118 in.) diameter bar cannot be inserted, unlock and pull out the plunger slightly. Then the stopper plate will be completely lowered and a 3.0 mm (0.118 in.) diameter bar can be inserted easily.
(5) Install the chain tensioner with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
(6) Remove the bar from the chain tensioner.
(f) Check the tension between the intake and exhaust camshaft timing sprockets.
2. INSTALL OIL PUMP SEAL Replacement
3. INSTALL TIMING CHAIN COVER Installation
4. INSTALL CRANKSHAFT POSITION SENSOR Installation
5. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Installation
6. INSTALL ENGINE MOUNTING BRACKET
(a) Install the engine mounting bracket with the 4 bolts.
Torque: 55 Nm (561 kgf-cm, 41 ft-lbf)
7. INSTALL ENGINE MOUNTING SPACER
(a) Install the engine mounting spacer with the 2 bolts.
Torque: 55 Nm (561 kgf-cm, 41 ft-lbf)
8. INSTALL ENGINE MOUNTING INSULATOR RH
(a) Install the engine mounting insulator RH with the 3 bolts and 4 nuts.
Torque: 52 Nm (530 kgf-cm, 38 ft-lbf)
9. INSTALL CRANKSHAFT PULLEY
(a) Align the hole of the crankshaft damper with the straight pin, then install the crankshaft damper.
(b) Using SST, hold the crankshaft damper and tighten the crankshaft bolt.
SST: 09213-58013
91111-50845
SST: 09330-00021
Torque: 128 Nm (1,305 kgf-cm, 95 ft-lbf)
NOTE: When installing SST, be careful that the bolt which holds SST does not interfere with the chain cover.
10. INSTALL WATER PUMP Installation
11. INSTALL DRIVE BELT Installation
12. CHECK DRIVE BELT TENSION Installation
13. INSTALL PURGE VSV
(a) Install the purge VSV with the bolt.
(b) Connect the hose and connector.
14. INSTALL CYLINDER HEAD COVER
(a) Apply seal packing to the 2 locations shown in the illustration, then install the cylinder head cover.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE:
- Remove any oil from the contact surface.
- Install the cylinder head cover within 3 minutes after applying seal packing.
- Do not start the engine within 2 hours of installing.
(b) Install the cylinder head cover with the 9 bolts and 2 nuts.
(c) Using several steps, tighten the bolts and nuts to the specified torque in the sequence shown in the illustration.
Torque: 10 Nm (102 kgf-cm, 74 in-lbf)
(d) Install the ignition coil with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
(e) Install the brake master cylinder reservoir cover to the cylinder head cover.
(f) Install the wire harness and brake master cylinder reservoir cover with the 3 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
(g) Connect the fuel injector connector and ignition coil connector.
15. INSTALL WINDSHIELD WASHER JAR
(a) Install the windshield washer with the 2 bolts and nut.
Torque: 4.9 Nm (50 kgf-cm, 43 in-lbf)
Torque: 14 Nm (143 kgf-cm, 10 ft-lbf)
Torque: 5.5 Nm (56 kgf-cm, 49 in-lbf)
(b) Connect the 2 connectors and wire harness.
16. INSTALL RESERVOIR BRACKET
(a) Install the reservoir bracket with the 3 bolts and connect the wire harness clamp.
Torque: 8.5 Nm (87 kgf-cm, 75 in-lbf)
17. INSTALL BRAKE MASTER CYLINDER RESERVOIR
(a) Attach the claw and install the master cylinder reservoir with the 2 bolts.
Torque: 8.5 Nm (87 kgf-cm, 75 in-lbf)
(b) Connect the connector.
18. INSTALL NO. 2 AIR CLEANER INLET
(a) Install the air cleaner inlet with the clip.
19. INSTALL AIR CLEANER ASSEMBLY
(a) Install the air cleaner with the 2 bolts and tighten the clamp.
Torque: 7.0 Nm (71 kgf-cm, 62 in-lbf)
Torque: 3.0 Nm (31 kgf-cm, 27 in-lbf)
(b) Connect the MAF meter connector and clamp.
(c) Connect the No. 1 air inlet, and then tighten the clamp.
20. INSTALL FRONT COWL TOP PANEL OUTER
21. INSTALL WINDSHIELD WIPER MOTOR AND WIPER LINK ASSEMBLY Installation
22. INSTALL COWL TOP VENTILATOR LOUVER RH
23. INSTALL COWL TOP VENTILATOR LOUVER LH
24. INSTALL HOOD TO COWL TOP SEAL
25. INSTALL FRONT WIPER ARM LH Installation
26. INSTALL FRONT WIPER ARM RH Installation
27. INSTALL WIPER ARM HEAD CAP
28. ADD ENGINE OIL Replacement
29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Installation
30. INSTALL REAR NO. 3 FLOOR BOARD Installation
31. INSTALL REAR DECK FLOOR BOARD Installation
32. INSTALL REAR NO. 2 FLOOR BOARD Installation
33. ADD ENGINE COOLANT Testing and Inspection
34. INSPECT FOR ENGINE COOLANT LEAK Testing and Inspection
35. INSTALL RADIATOR SUPPORT OPENING COVER
36. INSTALL NO. 4 CENTER ENGINE UNDER COVER
37. INSTALL NO. 3 ENGINE UNDER COVER
38. INSTALL FRONT WHEELS
39. PERFORM INITIALIZATION
(a) Perform initialization Repair Instruction - Initialization.
NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative battery terminal.