Timing Chain: Service and Repair
TIMING CHAINCOMPONENTS (Part 1):
COMPONENTS (Part 2):
COMPONENTS (Part 3):
COMPONENTS (Part 4):
COMPONENTS (Part 5):
COMPONENTS (Part 6):
COMPONENTS (Part 7):
COMPONENTS (Part 8):
COMPONENTS (Part 9):
COMPONENTS (Part 10):
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
2. REMOVE BATTERY
3. DRAIN ENGINE COOLANT
4. DRAIN ENGINE OIL
5. REMOVE ENGINE ASSEMBLY
6. REMOVE OIL LEVEL GAGE GUIDE
(a) Remove the oil level gauge.
(b) Remove the bolt and pull out the oil level gauge guide.
(c) Remove the O-ring from the oil level gauge guide.
7. REMOVE WATER INLET
8. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
9. REMOVE NO.2 IDLER PULLEY SUB-ASSEMBLY
(a) Remove the 2 bolts, then remove the idler pulley No. 2.
10. REMOVE NO.1 IDLER PULLEY SUB-ASSEMBLY
(a) Remove the bolt, then remove the idler pulley No. 1.
11. REMOVE CRANKSHAFT PULLEY
12. REMOVE NO.2 OIL PAN SUB-ASSEMBLY
(a) Remove the 15 bolts and 2 nuts.
(b) Insert the blade of SST between the oil pan and oil pan No. 2, cut off applied sealer and remove the oil pan No. 2.
SST 09032-00100
NOTICE:
^ Be careful not to damage the contact surfaces of the oil pan and oil pan No. 2
13. REMOVE OIL STRAINER SUB-ASSEMBLY
(a) Remove the 2 nuts, then remove the oil strainer and gasket.
14. REMOVE OIL PAN SUB-ASSEMBLY
(a) Remove the 17 bolts and 2 nuts.
(b) Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block.
NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pan.
15. REMOVE INTAKE AIR SURGE TANK
16. REMOVE IGNITION COIL ASSEMBLY
17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
19. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
20. REMOVE VVT SENSOR
21. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
22. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
23. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Using the crankshaft pulley set bolt, turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block.
(b) Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration.
If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks as above.
24. REMOVE NO.1 CHAIN TENSIONER ASSEMBLY
NOTICE:
^ Never rotate the crankshaft with the chain tensioner removed.
^ When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first.
(a) While turning the stopper plate of the tensioner upward, push in the plunger of the chain tensioner as shown in the illustration.
(b) While turning the stopper plate of the tensioner down ward, insert a bar of [diameter] 3.5 mm (0.138) into the holes in the stopper plate and tensioner to fix the stopper plate.
(c) Remove the 2 bolts, then remove the chain tensioner.
25. REMOVE CHAIN TENSIONER SLIPPER
26. REMOVE IDLE SPROCKET ASSEMBLY
(a) Using a 10 mm hexagon wrench, remove the idle gear shaft No. 2, idle gear No. 1 and idle gear shaft No. 1.
27. REMOVE NO.2 CHAIN VIBRATION DAMPER
(a) Remove the 2 chain vibration dampers No. 2.
28. REMOVE CHAIN SUB-ASSEMBLY
INSTALLATION
1. INSTALL CHAIN TENSIONER SLIPPER
2. INSTALL NO.1 CHAIN TENSIONER ASSEMBLY
(a) While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration.
(b) While turning the stopper plate of the tensioner counterclockwise, insert a bar of [diameter] 35 mm (0.138 inch) into the holes in the stopper plate and tensioner to fix the stopper plate.
(c) Install the chain tensioner with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7.4 ft. lbs.)
3. INSTALL CHAIN SUB-ASSEMBLY
(a) Set the No. 1 cylinder to TDC/compression.
(1) Align the timing marks of the camshaft timing gears and bearing caps.
(2) Using the crankshaft pulley set bolt, turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block.
(b) Align the yellow mark link with the timing mark of the crankshaft timing link.
(c) Align the orange mark links with the timing marks of the camshaft timing gears, and install the chain.
4. INSTALL NO.2 CHAIN VIBRATION DAMPER
(a) Install the 2 chain vibration dampers No. 2.
5. INSTALL IDLE SPROCKET ASSEMBLY
(a) Apply a light coat of engine oil to rotating surface of the idle gear shaft No. 1.
(b) Temporarily install the idle gear shaft No. 1 together with idle gear shaft No. 2 while aligning the knock pin of the idle gear shaft No. 1 with the knock pin groove of the cylinder block.
NOTICE: Be careful of the idle gear direction.
(c) Using 10 mm hexagon wrench, tighten the idle gear shaft No. 2.
Torque: 60 Nm (612 kgf-cm, 44 ft. lbs.)
(d) Remove the bar from the chain tensioner.
6. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
7. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
8. INSTALL VVT SENSOR
9. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
11. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
12. INSTALL IGNITION COIL ASSEMBLY
13. INSTALL INTAKE AIR SURGE TANK
14. INSTALL OIL PAN SUB-ASSEMBLY
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan.
(b) Install a new O-ring onto the oil pump.
(c) Apply a continuous bead of the seal packing (diameter 3 to 4 mm (0.12 to 0.16 inch)) to the oil pan as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE: Install the oil pan within 3 minutes of applying the seal packing. Tighten the oil pan bolts and nuts within 15 minutes of installing the oil pan. Otherwise, the seal packing must be removed and reapplied.
(d) Install the oil pan with the 17 bolts and 2 nuts, and tighten the bolts and nuts uniformly in several steps.
Torque:
10 Nm (102 kgf-cm, 7.4 ft. lbs.) for 10 mm (0.39 inch) head
21 Nm (214 kgf-cm, 16 ft. lbs.) for 12 mm (0.47 inch) head
HINT: Each bolt length is as follows:
15. INSTALL OIL STRAINER SUB-ASSEMBLY
(a) Install a new gasket and the oil strainer with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
16. INSTALL NO.2 OIL PAN SUB-ASSEMBLY
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pan and oil pan No. 2.
(b) Apply a continuous bead of seal packing (diameter 3 to 4 mm (0.12 to 0.16 inch)) as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE: Install the oil pan No. 2 within 3 minutes of applying the seal packing. Tighten the oil pan No. 2 bolts and nut within 15 minutes of installing the oil pan. Otherwise, the seal packing must be removed and reapplied.
(c) Install the oil pan No. 2 with the 15 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque:
9.0 Nm (92 kgf-cm, 80 inch lbs.) for bolts
10 Nm (102 kgf-cm, 7.4 ft. lbs.) for nuts
17. INSTALL CRANKSHAFT PULLEY
(a) Using SST, install the pulley set bolt.
SST 09213-54015 (91651-60855), 09330-00021
Torque: 250 Nm (2,549 kgf-cm, 184 ft. lbs.)
18. INSTALL NO.1 IDLER PULLEY SUB-ASSEMBLY
(a) Install the idler pulley with the bolt.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)
HINT: DOUBLE is marked on the idler pulley No. 1 to distinguish it from the idler pulley No. 2.
19. INSTALL NO.2 IDLER PULLEY SUB-ASSEMBLY
(a) Install the 2 idler pulleys with the 2 bolts.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
20. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
NOTICE: A bolt in position A is not reusable.
HINT: Each bolt length is as follows:
(a) Use a new bolt in position A.
(b) Finger-tighten the bolts in positions A and E and install the bracket.
(c) Tighten the bolts in positions A and E.
Torque: 36 Nm (267 kgf-cm, 27 ft. lbs.)
(d) Tighten the bolts in positions B, C and D.
Torque: 36 Nm (267 kgf-cm, 27 ft. lbs.)
21. INSTALL WATER INLET
22. INSTALL OIL LEVEL GAGE GUIDE
(a) Install a new O-ring onto the oil level gauge guide.
(b) Apply a light coat of engine oil to the O-ring.
(c) Push the oil level gauge guide end into the guide hole of the oil pan.
(d) Install the oil level gauge guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
(e) Install the oil level gauge guide.
23. INSTALL ENGINE ASSEMBLY
24. INSTALL BATTERY
25. ADD ENGINE COOLANT
26. ADD ENGINE OIL
27. CHECK FOR ENGINE COOLANT LEAKAGE
28. CHECK FOR ENGINE OIL LEAKAGE
29. CHECK FOR FUEL LEAKAGE
30. CHECK FOR EXHAUST GAS LEAKAGE
31. INSPECT IGNITION TIMING
32. INSPECT ENGINE IDLING SPEED
33. INSPECT CO/HC