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40. INSTALL CRANKSHAFT TIMING SPROCKET
(a) Install the 2 keys and crankshaft timing sprocket as
shown in the illustration.
41. INSTALL IDLE SPROCKET ASSEMBLY
(a) Apply a light coat of engine oil to the rotating surface
of the No. 1 idle gear shaft.
(b) Temporarily install the No. 1 idle gear shaft and idle
sprocket with the No. 2 idle gear shaft while aligning
the knock pin of the No. 1 idle gear with the knock
pin groove of the cylinder block.
NOTICE:
Be careful of the idle gear direction.
HINT:
Check that no foreign objects are on the No. 1 and
No. 2 idle gear shafts.
(c) Using a 10 mm hexagon wrench, tighten the No. 2
idle gear shaft.
Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf)
HINT:
After installing the idle sprocket assembly, check
that the idle sprocket turns smoothly.
42. INSTALL CHAIN SUB-ASSEMBLY
(a) Align the mark plate and timing marks as shown in
the illustration and install the chain.
HINT:
The camshaft mark plate is orange.
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(b) Do not pass the chain over the crankshaft, just put it
on it.
(c) Turn the camshaft timing gear assembly on the
bank 1 counterclockwise to tighten the chain
between the banks.
NOTICE:
When the idle sprocket is reused, align the chain
plate with the mark where the plate had been in
order to tighten the chain between the banks.
(d) Align the mark plate and timing marks as shown in
the illustration and install the chain onto the
crankshaft timing sprocket.
HINT:
The crankshaft mark plate is yellow.
(e) Temporarily tighten the pulley set bolt.
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(f) Turn the crankshaft clockwise to set it to the RH
block bore center line (TDC / compression).
43. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper.
44. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
(a) Move the stopper plate upward to release the lock,
and push the plunger deep into the tensioner.
(b) Move the stopper plate downward to set the lock,
and insert a hexagon wrench into the hole of the
stopper plate.
(c) Install the chain tensioner with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
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(d) Remove the hexagon wrench of the chain tensioner.
Check that each timing mark is aligned with the
crankshaft at the TDC / compression.
(e) Remove the pulley set bolt.
45. INSTALL TIMING CHAIN CASE OIL SEAL
(a) Using SST, tap in a new oil seal until its surface is
flush with the timing gear case edge.
SST 09223-22010, 09506-35010
NOTICE:
• Keep the lip free of foreign matter.
• Do not tap on the oil seal at an angle.
• Make sure that the oil seal edge does not
stick out of the timing chain case.
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46. INSTALL WATER PUMP ASSEMBLY
(a) Install a new gasket and the water pump assembly
with the 8 bolts.
Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf)
NOTICE:
Be sure to replace the bolts indicated by A with
new ones or reuse them after applying adhesive
1344.
47. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
(a) Apply seal packing in a continuous line to the
engine unit as shown in the following illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three
Bond 1207B or equivalent
Seal diameter:
3.0 mm (0.118 in.)
NOTICE:
• Be sure to clean and degrease the contact
surfaces, especially the surfaces indicated by
C in the illustration.
• When the contact surfaces are wet, wipe them
with an oil-free cloth before applying seal
packing.
• Install the chain cover within 3 minutes.
• Do not start the engine for at least 2 hours
after installing.
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(b) Apply seal packing in a continuous line to the timing
chain cover as shown in the following illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three
Bond 1207B or equivalent
Toyota Genuine Seal Packing 1282B, Three
Bond 1282B or equivalent
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NOTICE:
• When the contact surfaces are wet, wipe them
with an oil-free cloth before applying seal
packing.
• Install the chain cover within 3 minutes and
tighten the bolts within 15 minutes after
applying seal packing.
• Do not start the engine for at least 2 hours
after installing.
Apply seal packing as follows
(c) Install a new gasket.
(d) Align the oil pump's drive rotor spline and the
crankshaft as shown in the illustration. Install the
spline and chain cover to the crankshaft.
(e) Temporarily tighten the timing chain cover with the
23 bolts and 2 nuts.
Area Seal Packing Diameter Application Position from Inside Seal Line
Continuous Line Area 4.5 mm or more (0.177 in.) 3.0 to 4.0 mm (0.118 to 0.158 in.)
Alternate Long and Dashed Line Area 3.5 mm or more (0.138 in.) 2.0 to 3.0 mm (0.079 to 0.118 in.)
Dashed Line Area 3.5 mm or more (0.138 in.) 3.0 to 4.0 mm (0.118 to 0.158 in.)
Diagonal Line Area 6.0 mm or more (0.236 in.) 5.0 mm (0.197 in.)
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Bolt length
NOTICE:
Make sure that there is no oil on the bolt and nut
threads.
(f) Fully tighten the bolts in this order: Area 1 and Area
2.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(g) Fully tighten the bolts in Area 3.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
HINT:
Tighten the bolts and nuts in the order of upper to
lower as shown in the illustration.
(h) Fully tighten the bolts in Area 4.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) for bolt A
21 N*m (214 kgf*cm, 15 ft.*lbf) for bolts
except bolt A
HINT:
Tighten the bolts in the order of lower to upper as
shown in the illustration.
(i) Install a new chain cover plate gasket and the chain
cover plate with the 4 bolts.
Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf)
48. INSTALL WATER INLET HOUSING
(a) Install 2 new O-rings.
HINT:
Apply a small amount of water or soapy water to O-
ring (A) in the illustration before installing it.
Item Length
Bolt A 40 mm (1.57 in.)
Bolt B 55 mm (2.17 in.)
Bolt C 25 mm (0.98 in.)
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