here is the installation directions for the gts timing. hope this helps ya
INSTALLATION
1. INSTALL VALVE TIMING CONTROLLER ASSEMBLY
AND CAMSHAFT TIMING SPROCKET
(a) Apply engine oil in the range from the tip of the intake
camshaft to 16 mm from that tip.
(b) Align the timing mark on the value timing controller assembly
with the knock pin, and install the value timing
controller assembly to the cam shaft.
NOTICE:
Do not push valve timing controller assembly to the camshaft
forcibly when installing it.
(c) Align the knock pin hole in the cam shaft timing sprocket
with the knock pin of the cam shaft, and exhaust the
sprocket to the cam shaft.
(d) Temporarily install the timing sprocket bolt.
(e) Hold the hexagon wrench head portion of the camshaft
with a wrench, and tighten the timing sprocket bolt.
Torque: 54 N·m (551 kgf·cm, 40 ft·lbf)
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.
(b) Using a crankshaft pulley bolt, turn the crankshaft and set
the set key on the crankshaft upward.
B00281
A10394
1ZZ-FE:
2ZZ-GE:
B00282
Timing
Mark
Mark
B00303
SST
A10395
Mark Mark
Timing Mark
ENGINE MECHANICAL
- TIMING CHAIN
EM-27
Author: Date:
1401
2004 CELICA (RM1066U)
3. INSTALL CHAIN VIBRATION DAMPER
Install the damper with the 2 bolts.
Torque:
1ZZ-FE 9.0 N·m (92 kgf·cm, 80 in.·lbf)
2ZZ-GE 20.5 N·m (209 kgf·cm, 15 ft·lbf)
4. INSTALL TIMING CHAIN AND CRANKSHAFT TIMING
SPROCKET
(a) Install the timing chain on the crankshaft timing sprocket
with the yellow color link aligned with the timing mark on
the crankshaft timing sprocket.
HINT:
If necessary, install the sprocket with SST.
SST 09223-22010
(b) 1ZZ-FE:
Install the timing chain on the camshaft timing sprockets
with the yellow color links aligned with the timing marks on
the camshaft timing sprockets.
(c) 2ZZ-GE:
Install the timing chain on the camshaft timing sprockets
with the orange color links aligned with the timing marks
on the camshaft timing sprockets.
A10402
Catch
Cylinder Head
Stopper
A01047
EM-28
ENGINE MECHANICAL
- TIMING CHAIN
Author: Date:
1402
2004 CELICA (RM1066U)
(d) Check that the tension between the intake camshaft timing
sprocket and crankshaft timing sprocket.
5. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the slipper with the bolt.
Torque:
1ZZ-FE 18.5 N·m (189 kgf·cm, 14 ft·lbf)
2ZZ-GE 20.5 N·m (209 kgf·cm, 15 ft·lbf)
(b) Check that the slipper moves is caught on the cylinder
head stopper.
NOTICE:
DO not turn the crankshaft.
6. INSTALL CRANK ANGLE SENSOR PLATE
Install the plate with the ”F” mark facing forward.
A07223
Chain
Cover
Groove
Cylinder
Head
Groove
Seal Width
1.5 mm
A B C
12 mm
6 mm
7 mm
4.5
mm
A
B
C
3 mm
A10403
Seal Width
4 - 5 mm
Seal Packing
ENGINE MECHANICAL
- TIMING CHAIN
EM-29
Author: Date:
1403
2004 CELICA (RM1066U)
7. 1ZZ-FE:
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.
(b) Apply seal packing to the timing chain cover as shown in
the illustration.
Seal packing:
Part No. 08826 - 00100 or equivalent
Install a nozzle that has been cut to a 1.5 mm (0.16
- 0.20 in.) opening.
HINT:
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.
(c) Apply seal packing to 2 locations as shown in the illustration.
Seal packing:
Part No. 08826 - 00080 or equivalent
Install a nozzle that has been cut to a 1.5 mm (0.16
- 0.20 in.) opening.
HINT:
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.
A11371
D
E
D D D
A
A
A
D
D
D
B
B
B
B C
C
E
EM-30
ENGINE MECHANICAL
- TIMING CHAIN
Author: Date:
1404
2004 CELICA (RM1066U)
(d) Install the timing chain cover, O-ring and water pump
with the 16 bolts and 2 nuts. Uniformly tighten the bolts
and nut in several passes.
Torque:
10 mm head:
9 N·m (92 kgf·cm, 80 in.·lbf) for C
13 N·m (133 kgf·cm, 10 ft·lbf) for D and E
11 N·m (113 kgf·cm, 8 ft·lbf) for B
12 mm head:
18.5 N·m (189 kgf·cm, 14 ft·lbf) for A
NOTICE:
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.
HINT:
Each bolt length in indicated in the illustration.
A 45 mm (1.77 in.)
B 35 mm (1.38 in.)
C 22 mm (0.87 in.)
D 25 mm (0.98 in.)
(e) Using a torx wench socket (E8), install the stud bolt.
Torque: 9.3 N·m (95 kgf·cm, 82 in.·lbf)
A10376
FIPG
Seal Width
1.5 mm
Gasket
A10396
Seal
Packing
Seal Width 4 - 5 mm
ENGINE MECHANICAL
- TIMING CHAIN
EM-31
Author: Date:
1405
2004 CELICA (RM1066U)
8. 2ZZ-GE:
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.
(b) Apply seal packing to the timing chain cover as shown in
the illustration.
Seal packing:
Part No. 08826-00100 or equivalent
Install a nozzle that has been cut to a 1.5 mm opening.
HINT:
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.
(c) Install the 2 gasket to the timing chain cover as shown in
the illustration.
(d) Apply seal packing to 4 locations as shown in the illustration.
Seal packing:
Part No. 08826-00080 or equivalent
Install a nozzle that has been cut to a 4 - 5 mm (0.16
- 0.20 in.) opening.
HINT:
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.
A10397
A
B
C
A
A
B
B
B
B
B
C
C
D
B
B B
D
C
B
A10388
2ZZ-GE:
EM-32
ENGINE MECHANICAL
- TIMING CHAIN
Author: Date:
1406
2004 CELICA (RM1066U)
(e) Install the timing chain cover, O-ring and water pump with
the 19 bolts. Uniformly tighten the bolts in several passes.
Torque:
A: 21 N·m (214 kgf·cm, 15 ft·lbf)
B: 11 N·m (113 kgf·cm, 8 ft·lbf)
C: 9.0 N·m (92 kgf·cm, 80 in.·lbf)
D: 9.0 N·m (92 kgf·cm, 80 in.·lbf)
NOTICE:
Pay attention not to wrap the chain and slipper over
the chain cover seal line.
After install the chain cover, must install the mounting
bracket and water pump within 15 minutes.
(f) Using a torx wrench socket (E8), install the stud bolt.
Torque: 9.3 N·m (95 kgf·cm, 82 in.·lbf)
9. 2ZZ-GE:
INSTALL EXHAUST MANIFOLD (See page
EM-67 )
10. 2ZZ-GE:
INSTALL EXHAUST MANIFOLD STAY
(See page EM-67 )
11. 2ZZ-GE:
INSTALL FRONT EXHAUST PIPE (See page EM-67 )
12. 1ZZ-FE:
INSTALL RH ENGINE MOUNTING BRACKET
(a) Apply seal packing to threads of the mounting bolt.
Seal packing:
Part No. 08826 - 00080 or equivalent
HINT:
Do not apply seal packing to 2 or 3 threads of the bolt end.
(b) Install the mounting bracket with the 3 bolts.
Torque: 47 N·m (479 kgf·cm, 35 ft·lbf)
13. 2ZZ-GE:
INSTALL RH ENGINE MOUNTING BRACKET
Install the mounting bracket with the 4 bolts.
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
14. INSTALL DRIVE BELT TENSIONER
(a) Check the appearance before installing the drive belt tensioner.
If in case of having the oil leakage, crack, and etc., replace the
drive belt tensioner.
A21007
SST
A07224
Raise
Push
Pin
Hook
A07317
Push
ENGINE MECHANICAL
- TIMING CHAIN
EM-33
Author: Date:
1407
2004 CELICA (RM1066U)
(b) Install the drive belt tensioner.
Torque:
Bolt
1ZZ-FE 69 N·m (704 kgf·cm, 51 ft·lbf)
2ZZ-GE 100 N·m (1,020 kgf·cm, 74 ft·lbf)
Nut 29 N·m (296 kgf·cm, 21 ft·lbf)
(c) Hook the tool on the hexagonal portion of the drive belt
tensioner bracket and operate drive belt tensioner 3 times
with full stroke.
HINT:
Take 3 seconds or more for 1 full stroke.
15. INSTALL CRANKSHAFT POSITION SENSOR
Torque: 9.0 N·m (92 kgf·cm, 80 in.·lbf)
16. 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.
SST 09960-10010 (09962-01000, 09963-01000)
Torque:
1ZZ-FE 138 N·m (1,409 kgf·cm, 102 ft·lbf)
2ZZ-GE 120 N·m (1,224 kgf·cm, 89 ft·lbf)
17. INSTALL CHAIN TENSIONER
(a) Check the chain tensioner.
(See page EM-16)
(b) Release the ratchet pawl, fully push in the plunger and apply
the hook to the pin so that the plunger cannot spring
out.
(c) Insert the O-ring with your hand until it reaches to the
chamfering position and install nut temporally. Then, by
tightening the nut, insert the chain tensioner to the installation
position.
HINT:
In the 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.
A10405
Disconnect
Hook
Pin
Turn
A10406
Plunger
Push Turn
A10407
A10387
2ZZ-GE:
1ZZ-FE:
EM-34
ENGINE MECHANICAL
- TIMING CHAIN
Author: Date:
1408
2004 CELICA (RM1066U)
(d) Tighten the 2 nuts.
Torque: 9.0 N·m (92 kgf·cm, 80 in.·lbf)
18. SET CHAIN TENSION
(a) Turn the crankshaft counterclockwise, and disconnect
the plunger knock pin from the hook.
(b) Turn the crankshaft clockwise, and check that the slipper
is pushed by the plunger.
HINT:
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.
19. CHECK VALVE TIMING
(a) Turn the crankshaft pulley, and align its groove with timing
mark ”0” of the timing chain cover.
NOTICE:
Always turn the crankshaft clockwise.
(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.
If not, turn the crankshaft 1 revolution (360
°) and align the
marks as above.
B00301
Seal
Packing
A21001
B00301
ENGINE MECHANICAL
- TIMING CHAIN
EM-35
Author: Date:
1409
2004 CELICA (RM1066U)
20. 1ZZ-FE:
INSTALL CYLINDER HEAD COVER
(a) Remove any old packing (FIPG) material.
(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.
HINT:
Part must be assembled within 3 minutes of application.
Otherwise the material must be remove and reapplied.
(d) Install the cylinder head cover with the 9 bolts, 2 seal
washers and 2 nuts.
Uniformly tighten the bolts and nuts, in the several
passes, in the sequence shown.
Torque:
w/o washer
11 N·m (113 kgf·cm, 8 ft·lbf)
w/ washer
9.0 N·m (92 kgf·cm, 80 in.·lbf)
(e) Connect the 2 PCV hoses to the cylinder head cover.
(f) Install the ignition coil (See page
IG-7 ).
21. 2ZZ-GE:
INSTALL CYLINDER HEAD COVER
(a) Remove any old packing (FIPG) material.
HINT:
When FIPG on the head cover gasket side cannot be eliminated
completely, replace the gasket.
(b) Apply seal packing to 2 locations as shown in the illustration.
Seal packing:
Part No. 08826-00080 or equivalent
A10386
A10385
A10381
2ZZ-GE:
EM-36
ENGINE MECHANICAL
- TIMING CHAIN
Author: Date:
1410
2004 CELICA (RM1066U)
(c) Install the gasket to the cylinder head cover.
HINT:
Part must be assembled within 3 minutes of application. Otherwise
the material must be remove and reapplied.
(d) Install a new O-ring to the cylinder head cover.
(e) Install the cylinder head cover and wire harness protector
with the9 bolts. Uniformly tighten the bolts, in the several
passes, in the sequence shown.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
(f) Connect the 2 PCV hoses to the cylinder head cover.
(g) Install a new gasket and No. 1 ventilation pipe with 2 nuts
and bolt.
Torque:
Nut 10 N·m (100 kgf·cm, 7 ft·lbf)
Bolt 25 N·m (255 kgf·cm, 18 ft·lbf)
(h) Connect the No. 3 ventilation hose to the No. 1 ventilation
pipe.
(i) Install the ignition coil (See page
IG-7 ).
22. INSTALL RH ENGINE MOUNTING INSULATOR
(a) 1ZZ-FE:
Install the RH engine mounting insulator with the 4 bolts
and 2 nuts.
Torque: 52 N·m (530 kgf·cm, 38 ft·lbf)
(b) 2ZZ-GE:
Install the RH engine mounting insulator with the 5 bolts
and 2 nuts.
Torque: 52 N·m (530 kgf·cm, 38 ft·lbf)
23. INSTALL PS PUMP
(a) Install the PS pump with the 2 through bolts and nuts.
Torque: 36 N·m (370 kgf·cm, 27 ft·lbf)
(b) Install the PS pump pulley with the pulley nut.
(c) Connect the PS oil pressure switch connector.
24. INSTALL GENERATOR AND DRIVE BELT
(See page
CH-17 )
25. 2ZZ-GE:
INSTALL AIR SWITCHING VALVE (See page EC-18 )
26. INSTALL RH ENGINE UNDER COVER
27. INSTALL RH FRONT WHEEL
ENGINE MECHANICAL
- TIMING CHAIN
EM-37
Author: Date:
1411
2004 CELICA (RM1066U)
28. FILL WITH ENGINE COOLANT (See page
CO-2 )
29. INSTALL FRONT FENDER APRON SEAL AND UPPER
RADIATOR SUPPORT SEAL
30. START ENGINE AND CHECK FOR COOLANT LEAKS
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