Removal

1GR-FE ENGINE MECHANICAL: TIMING CHAIN (for 2WD): REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE

Service Precautions

2. REMOVE BATTERY

3. DRAIN ENGINE COOLANT Service and Repair

4. DRAIN ENGINE OIL Removal

5. REMOVE ENGINE ASSEMBLY

Removal

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 Removal

8. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY Removal

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 Removal

12. REMOVE NO.2 OIL PAN SUB-ASSEMBLY

(a) Remove the 15 bolts and 2 nuts.





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





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 Removal

16. REMOVE IGNITION COIL ASSEMBLY Removal

17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Removal

18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH Removal

19. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Removal

20. REMOVE VVT SENSOR Removal

21. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY Removal

22. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Replacement

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 dia 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