Cadena de Tiempo Corolla 1.8L 2002 Al 2004

2004 Toyota Corolla S
2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder
INSTALLATION
1. Install Camshaft Timing Sprocket And VVT Timing Sprocket.

a. Align the camshaft knock pin with the knock pin groove on the sprocket side with the timing mark,
and slide on the camshaft timing sprocket and VVT timing sprocket.
Fig. 50: Identifying Camshaft & VVT Timing Sprocket Timing Marks
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
b. Temporarily install the timing sprocket bolt.

c. Hold the hexagon wrench head portion of the camshaft with a wrench, and tighten the timing
sprocket bolt.Torque: 54 N.m (550 kgf.cm, 40 ft.lbf) .
miércoles, 01 de enero de 2003 12:36:58

12:36:54 a.m. Page 1 © 2011 Mitchell Repair Information Company, LLC.
Fig. 51: Locating Hexagon Wrench Head Portion Of Camshaft & Timing Sprocket Bolts
2. Set No. 1 Cylinder To TDC Compression.

a. Turn the hexagonal wrench head portion of the camshafts, and align the point marks of the
camshaft timing sprockets.
miércoles, 01 de enero de 2003 12:36:54 a.m. Page 2 © 2011 Mitchell Repair Information Company, LLC.
Fig. 52: Aligning Camshaft Point Marks

b. Using a crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward.
Fig. 53: Identifying Crankshaft Set Key

3. Install Chain Vibration Damper With The 2 Bolts. .
Torque: 9 N.m (92 kgf.cm, 80 in..lbf)
Fig. 54: Locating Chain Vibration Damper Mounting Bolts

4. Install Timing Chain And Crankshaft Timing Sprocket.
NOTE: If necessary, install the sprocket with SST# 09223-22010.
Fig. 55: Aligning Crankshaft Timing Sprocket & Chain Alignment Marks
Fig. 56: Identifying SST# 09223-22010

a. Install the timing chain on the crankshaft timing sprocket with the #1 mark link aligned with the
timing mark on the crankshaft timing sprocket.
b. Install the timing chain on the camshaft timing sprocket and VVT timing sprocket with the #53 and
#67 mark links aligned with the timing marks on the camshaft timing sprocket and VVT timing
sprocket.
Fig. 57: Aligning Camshaft Timing Sprocket & VVT Timing Sprocket Timing Marks
c. Check that the tension between the VVT timing sprocket and crankshaft timing sprocket.
NOTE: Do not turn the crankshaft.
Fig. 58: Locating Slipper Mounting Bolt & Cylinder Head Stopper
5. Install chain tensioner slipper/slipper with the bolt.
Torque: 18.5 N.m (189 kgf.cm, 14 ft.lbf).
Check that the slipper is held on the cylinder head stopper.
6. Install Crank Angle Sensor Plate With The"F" Mark Facing Forward.
Fig. 59: Locating Crank Angle Sensor Plate "F" Mark

7. Install Timing Chain Cover And Water Pump.

a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces
of the timing chain cover, cylinder head and cylinder block.
Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from
the gasket surfaces and sealing grooves.
Thoroughly clean all components to remove all the loose material.
Using a non-residue solvent, clean both sealing surfaces.
NOTE: Avoid applying an excessive amount to the surface.
Install a nozzle that has been cut to a 4 - 5 mm (0.16 - 0.20 in.)

opening.
Parts must be assembled within 3 minutes of application.
Otherwise the material must be removed and reapplied.
Immediately remove nozzle from the tube and reinstall cap.
Fig. 60: Identifying Legend Locations For Seal Packing Application Positions
Fig. 61: Seal packing Legend & Position Specifications

b. Apply seal packing to the timing chain cover as shown in the illustration.Seal packing: Part No.
08826-00100 or equivalent .
NOTE: Install a nozzle that has been cut to a 4 - 5 mm (0.16 - 0.20 in.)
opening.
Avoid applying an excessive amount to the surface.
Parts must be assembled within 3 minutes of application.
Otherwise the material must be removed and reapplied.
Immediately remove nozzle from the tube and reinstall cap.
Fig. 62: Identifying Seal Packing Application Positions

c. Apply seal packing to 2 locations as shown in the illustration.Seal packing: Part No. 08826-00080
or equivalent .
NOTE: Pay attention not to wrap the chain and slipper over the chain
cover seal line.
After installing the chain cover, must install the mounting
bracket and water pump within 15 minutes.
d. Install the timing chain cover, O-ring and water pump with the 17 bolts and nut in locations called
out in Fig. 63. Uniformly tighten the bolts and nut in several passes.
Torque:
9 N.m (92 kgf.cm, 80 in..lbf) for 10 mm head (C) .

13 N.m (133 kgf.cm, 10 in..lbf) for 10 mm head (A) .
11 N.m (113 kgf.cm, 8 ft.lbf) for 10 mm head (others) .

18.5 N.m (189 kgf.cm, 14 ft.lbf) for 12 mm head .
Each bolt length in indicated in the illustration.
Bolt "A" 45 mm (1.77 in.).

Bolt "B" 35 mm (1.38 in.).
Bolt "C" 30 mm (1.18 in.).
Bolt "D" 25 mm (0.98 in.).
Fig. 63: Identifying Bolt Locations

e. Using a torx wench socket (E8), install the stud bolt. Torque: 9.3 N.m (95 kgf.cm, 82 in..lbf) .
8. Install RH Engine Mounting Bracket.
NOTE: Do not apply seal packing to 2 or 3 threads of the bolt end.
Fig. 64: Locating Crankshaft Position Sensor, Drive Belt Tensioner & Mounting Bracket
Bolts
a. Apply seal packing to threads of the mounting bolt. Seal packing: Part No. 08826-00080 or
equivalent .
b. Install the mounting bracket with the 3 bolts. Torque: 47 N.m (479 kgf.cm, 35 ft.lbf) .
9. Install Drive Belt Tensioner.
a. Install the drive belt tensioner with the bolt and nut.
Torque:
69 N.m (704 kgf.cm, 51 ft.lbf) for bolt .

29 N.m (296 kgf.cm, 21 ft.lbf) for nut .
NOTE: Take 3 seconds or more for 1 full stroke.
b. Hook the tool on the hexagonal portion of the drive belt tensioner bracket and operate drive belt
tensioner 3 times with full stroke.
10. Install Crankshaft Position Sensor.
Torque: 9 N.m (92 kgf.cm, 80 in..lbf).
11. Install Crankshaft Pulley.

a. Clean the crankshaft pulley inside.
b. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
c. Using SST, install the pulley bolt.Torque: 138 N.m (1,409 kgf.cm, 102 ft.lbf) . SST 09213-70011,
09330-00021.
Fig. 65: Installing Crankshaft Pulley Bolt

12. Install Chain Tensioner.

a. Check the chain tensioner. See 2 in INSPECTION under TIMING CHAIN.
b. Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger
cannot spring out.
Fig. 66: Locating Chain Tensioner Hook & Pin

NOTE: In case that the hook is released while pushing in, apply the
hook again and push the tensioner in.
Pay attention not to catch the O-ring as it is built in the chain
tensioner previously.
Fig. 67: Installing Chain Tensioner

c. Push the chain tensioner into the timing chain cover, and install the 2 nuts.Torque: 9 N.m (92
kgf.cm, 80 in..lbf) .
13. Set Chain Tension.
a. Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook.
Fig. 68: Confirming Chain Tension (1 Of 2)

NOTE: If the plunger does not spring out, press the slipper into the chain
tensioner with a screwdriver or your finger so that the hook is released
from the knock pin and the plunger springs out.
Fig. 69: Confirming Chain Tensioner Plunger Position

Fig. 70: Confirming Chain Tension (2 Of 2)

b. Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.
14. Check Valve Timing.
CAUTION: Always turn the crankshaft clockwise.
a. Turn the crankshaft pulley, and align its groove with timing mark 0° of the timing chain cover.
b. Check that the point marks of the camshaft timing sprockets are in straight line on the timing chain
cover surface as shown in the illustration.
Fig. 71: Identifying Correct Camshaft & VVT Timing Sprocket Point Marks Alignment
If not, turn the crankshaft 1 revolution (360°) and align the marks as above.
15. Install Cylinder Head Cover.

a. Remove any old packing (FIPG) material.
NOTE: Part must be assembled within 3 minutes of application. Otherwise

the material must be remove and reapplied.
Fig. 72: Identifying Seal Packing Application Points

b. Apply seal packing to 2 locations as shown in the illustration. Seal packing: Part No. 08826-
00080 or equivalent .
c. Install the gasket to the cylinder head cover.
If the gasket has damage, replace a new one.
d. Install the cylinder head cover and cable bracket with the 9 bolts, 2 seal washers and 2 nuts.
Uniformly tighten the bolts and nuts, in the several passes, in the sequence shown.
Fig. 73: Identifying Cylinder Head Cover & Cable Bracket Bolt & Nut Tightening Sequence
Torque:
11 N.m (113 kgf.cm, 8 ft.lbf) for without washer .

9 N.m (92 kgf.cm, 80 in..lbf) for with washer .
e. Connect the 2 PCV hoses to the cylinder head cover.
f. Install the 4 ignition coils with 4 bolts.
g. Install the engine wire with 2 bolts.
h. Connect the ignition coil connectors.
i. Install the No. 2 cylinder head cover with 2 nuts and 2 clips.
16. Install RH Engine Mounting Insulator.
a. Install the RH engine mounting insulator with the 4 bolts and 2 nuts.
Fig. 74: Identifying Engine Mounting Insulator Bolt & Nut Placement
Torque:
63.7 N.m (650 kgf.cm, 47 ft.lbf) for bolt A .

25.5 N.m (260 kgf.cm, 19 ft.lbf) for bolt B .
52.0 N.m (530 kgf.cm, 38 ft.lbf) for nut .
b. With A/C: Install the bolt holding the A/C piping clamp to the RH engine mounting insulator.
17. Install PS Pump.
a. Install the PS pump with the 2 through bolts and nuts.Torque: 37 N.m (370 kgf.cm, 27 ft.lbf) .
b. Install the PS pump pulley with the pulley nut.
c. Using SST, torque the pulley nut. Torque: 43 N.m (440 kgf.cm, 32 ft.lbf) . SST 09960-10010
(09962-01000, 09963-01000).
Fig. 75: Installing Power Steering Pump Pulley

d. Connect the PS oil pressure switch connector.

18. Install Generator and Drive Belt .
19. Install RH Engine Under Cover.
20. Install RH Front Wheel.
21. Install Washer Tank.
22. Fill With Engine Coolant.
23. Start Engine And Check For Coolant Leaks.

Cadena de Tiempo Corolla 1.8L 2002 Al 2004

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Cadena de Tiempo Corolla 1.8L 2002 Al 2004

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2004 Toyota Corolla S

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

1. Install Camshaft Timing Sprocket And VVT Timing Sprocket.

b. Temporarily install the timing sprocket bolt.

miércoles, 01 de enero de 2003 12:36:58

2. Set No. 1 Cylinder To TDC Compression.

Fig. 52: Aligning Camshaft Point Marks

Fig. 53: Identifying Crankshaft Set Key

3. Install Chain Vibration Damper With The 2 Bolts. .

Torque: 9 N.m (92 kgf.cm, 80 in..lbf)

Fig. 54: Locating Chain Vibration Damper Mounting Bolts

4. Install Timing Chain And Crankshaft Timing Sprocket.

NOTE: If necessary, install the sprocket with SST# 09223-22010.

Fig. 56: Identifying SST# 09223-22010

NOTE: Do not turn the crankshaft.

5. Install chain tensioner slipper/slipper with the bolt.

Torque: 18.5 N.m (189 kgf.cm, 14 ft.lbf).

Check that the slipper is held on the cylinder head stopper.

Fig. 59: Locating Crank Angle Sensor Plate "F" Mark

7. Install Timing Chain Cover And Water Pump.

NOTE: Avoid applying an excessive amount to the surface.

Install a nozzle that has been cut to a 4 - 5 mm (0.16 - 0.20 in.)

Fig. 61: Seal packing Legend & Position Specifications

Fig. 62: Identifying Seal Packing Application Positions

9 N.m (92 kgf.cm, 80 in..lbf) for 10 mm head (C) .

11 N.m (113 kgf.cm, 8 ft.lbf) for 10 mm head (others) .

Each bolt length in indicated in the illustration.

Bolt "A" 45 mm (1.77 in.).

Fig. 63: Identifying Bolt Locations

NOTE: Do not apply seal packing to 2 or 3 threads of the bolt end.

69 N.m (704 kgf.cm, 51 ft.lbf) for bolt .

NOTE: Take 3 seconds or more for 1 full stroke.

Torque: 9 N.m (92 kgf.cm, 80 in..lbf).

11. Install Crankshaft Pulley.

Fig. 65: Installing Crankshaft Pulley Bolt

12. Install Chain Tensioner.

Fig. 66: Locating Chain Tensioner Hook & Pin

Fig. 67: Installing Chain Tensioner

Fig. 68: Confirming Chain Tension (1 Of 2)

Fig. 69: Confirming Chain Tensioner Plunger Position

Fig. 70: Confirming Chain Tension (2 Of 2)

CAUTION: Always turn the crankshaft clockwise.

15. Install Cylinder Head Cover.

NOTE: Part must be assembled within 3 minutes of application. Otherwise

Fig. 72: Identifying Seal Packing Application Points

If the gasket has damage, replace a new one.

11 N.m (113 kgf.cm, 8 ft.lbf) for without washer .

63.7 N.m (650 kgf.cm, 47 ft.lbf) for bolt A .

Fig. 75: Installing Power Steering Pump Pulley

d. Connect the PS oil pressure switch connector.

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