Removal

1GR-FE ENGINE MECHANICAL: TIMING CHAIN: REMOVAL

REMOVAL

1. REMOVE POWER STEERING LINK ASSEMBLY

HINT: Removal

2. REMOVE DIFFERENTIAL CARRIER ASSEMBLY FRONT (for 4WD)

HINT:

3. DRAIN ENGINE COOLANT Service and Repair
4. DRAIN ENGINE OIL Removal
5. REMOVE BATTERY
6. REMOVE V-BANK COVER Removal
7. REMOVE RADIATOR SUPPORT SEAL UPPER
(a) Remove the 11 clips and radiator support seal upper.
8. LOOSEN FLUID COUPLING ASSEMBLY Removal
9. REMOVE FAN AND GENERATOR V BELT Removal
10. REMOVE FLUID COUPLING ASSEMBLY Removal
11. DISCONNECT NO. 2 VENTILATION HOSE
12. REMOVE AIR CLEANER ASSEMBLY Removal
13. REMOVE OIL LEVEL GAUGE 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.
14. REMOVE WATER INLET
15. SEPARATE VANE PUMP ASSEMBLY

(a) Disconnect the P/S oil pressure switch connector.
(b) Remove the 2 bolts, and separate the vane pump.

NOTE: Do not hit the pulley to other parts when separating the vane pump.

HINT: The vane pump is suspended securely.

16. REMOVE GENERATOR ASSEMBLY Removal
17. SEPARATE COOLER COMPRESSOR ASSEMBLY Removal
18. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

(a) Remove the 5 bolts and V-ribbed belt tensioner.
19. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY

HINT: Use the same procedure for both No. 2 idler pulleys.

(a) w/ Idler Pulley Cover Plate:

(1) Remove the bolt, No. 2 idler pulley cover plate, idler pulley and idler pulley cover plate.
(b) w/o Idler Pulley Cover Plate:

(1) Remove the bolt, No. 2 idler pulley cover plate and idler pulley.
20. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY
(a) Remove the bolt and idler pulley.
21. REMOVE CRANKSHAFT PULLEY

(a) Using SST, hold the crankshaft pulley and loosen the pulley set bolt.
SST: 09213-54015
91651-60855
SST: 09330-00021

(b) Using the pulley set bolt and SST, remove the crankshaft pulley.
SST: 09950-50013
09951-05010
09952-05010
09953-05020
09954-05031
22. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

(a) Remove the 10 bolts and 2 nuts.

(b) Insert the blade of oil pan seal cutter between the oil pan and No. 2 oil pan, cut off applied sealer and remove the No. 2 oil pan.

NOTICE:
- Be careful not to damage the contact surfaces of the oil pan and No. 2 oil pan.
- Be careful not to damage the No. 2 oil pan flange.

23. REMOVE OIL STRAINER SUB-ASSEMBLY

(a) Remove the 2 nuts, oil strainer and gasket.
24. REMOVE OIL PAN SUB-ASSEMBLY

(a) Remove the 4 housing bolts.
(b) Remove the flywheel housing under cover.

(d) Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block as shown in the illustration.

NOTE: Be careful not to damage the contact surfaces of the cylinder block and oil pan.

(e) Remove the O-ring from the oil pump.
25. REMOVE INTAKE AIR SURGE TANK Removal
26. REMOVE IGNITION COIL ASSEMBLY
27. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Disassembly
28. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH Disassembly
29. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) Disconnect the 2 oil control valve connectors.
(b) Remove the 2 bolts and 2 camshaft timing oil control valves.
30. REMOVE VVT SENSOR Removal
31. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY Disassembly
32. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
33. SET NO. 1 CYLINDER TO TDC / COMPRESSION

(a) Install the crankshaft pulley set bolt, and 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 caps as shown in the illustration.
If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks as above.
34. 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 clockwise, push in the plunger of the chain tensioner as shown in the illustration.
(b) While turning the stopper plate of the tensioner counterclockwise, insert a bar of dia3.5 mm (0.138 in.) into the holes on the stopper plate and tensioner to fix the stopper plate.
(c) Remove the 2 bolts and chain tensioner.
35. REMOVE CHAIN TENSIONER SLIPPER
36. REMOVE NO. 1 IDLE GEAR SHAFT

(a) Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, No. 1 idle gear and No. 1 idle gear shaft.
37. REMOVE NO. 2 CHAIN VIBRATION DAMPER
(a) Remove the 2 No. 2 chain vibration dampers.
38. REMOVE CHAIN SUB-ASSEMBLY