Timing Chain: Service and Repair

TIMING CHAIN

REMOVAL
1. REMOVE HOOD SUB-ASSEMBLY
2. REMOVE FRONT WHEEL RH
3. REMOVE ENGINE UNDER COVER LH
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE FRONT FENDER APRON SEAL RH
6. DRAIN ENGINE OIL
(a) Install a new gasket and the drain plug after draining engine oil.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
7. REMOVE FRONT EXHAUST PIPE ASSEMBLY

8. REMOVE ENGINE MOVING CONTROL ROD W/ BRACKET
(a) Remove the 3 bolts and control rod.
9. REMOVE ENGINE MOUNTING STAY NO.2 RH
10. REMOVE ENGINE MOUNTING BRACKET NO.2 RH
11. REMOVE FAN AND GENERATOR V BELT
12. REMOVE NO.1 ENGINE COVER SUB-ASSEMBLY
13. REMOVE ENGINE WIRE
14. REMOVE GENERATOR ASSEMBLY
15. REMOVE VANE PUMP ASSEMBLY
16. REMOVE IGNITION COIL ASSEMBLY
17. DISCONNECT VENTILATION HOSE
18. DISCONNECT VENTILATION HOSE NO.2

19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Remove the bolt and disconnect the engine wire harness clamp.
(b) Remove the 8 bolts and 2 nuts, and disconnect the cylinder head cover.
20. SET NO.1 CYLINDER TO TDC/COMPRESSION

21. REMOVE CRANKSHAFT PULLEY
(a) Using SST, fix the pulley and loosen the bolt.
SST 09960-10010 (09962-01000, 09963-01000)

(b) Using SST, remove the bolt and pulley.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04030, 09954-04010, 09955-04041, 09957-04010, 91111-51014)
22. REMOVE CRANKSHAFT POSITION SENSOR

23. REMOVE OIL PAN SUB-ASSEMBLY
(a) Remove the 12 bolts and 2 nuts.

(b) Insert the blade of SST between the crankcase and oil pan. Cut through the sealer and remove the oil pan.
SST 09032-00100

NOTICE: Be careful not to damage the contact surface of the cylinder block and oil pan.

24. REMOVE NO.1 CHAIN TENSIONER ASSEMBLY
(a) Remove the 2 nuts, tensioner and gasket.

NOTICE: Do not revolve the crankshaft without the tensioner.

25. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(a) Remove the bolt, nut and tensioner.

26. INSTALL ENGINE HANGERS
(a) Install the engine hanger No. 1 and No. 2 with the bolts as shown in the illustration.

Parts No.:

Torque: 38 Nm (387 kgf-cm, 28 ft. lbs.)

27. REMOVE ENGINE MOUNTING INSULATOR
(a) Attach the engine chain hoist to the engine hangers.

CAUTION: Do not attempt to hang the engine by hooking the chain to any other part.

(b) Remove the bolt and disconnect the engine mounting insulator FR.

(d) Remove the bolt and disconnect the steering gear return hose clamp from the frame.

(e) Remove the 4 nuts from the engine mounting insulator RH.
(f) Raise the engine and remove the engine mounting insulator RH.

28. REMOVE ENGINE MOUNTING BRACKET RH
(a) Remove the 3 bolts and engine mounting bracket.
29. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

30. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
(a) Remove the crankshaft position sensor plate.

31. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the bolt and chain tensioner slipper.

32. REMOVE CHAIN VIBRATION DAMPER NO.1
(a) Remove the 2 bolts and chain vibration damper.

33. REMOVE TIMING CHAIN GUIDE
(a) Remove the bolt and timing chain guide.

34. REMOVE CHAIN SUB-ASSEMBLY
(a) Remove the chain sub-assembly.

35. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
(a) Remove the crankshaft timing sprocket.

36. REMOVE NO.2 CHAIN SUB-ASSEMBLY
(a) Turn the crankshaft counterclockwise by 90°, and align an adjusting hole of the oil pump driven sprocket with the groove of the oil pump.

(b) Put a bar ([diameter]4 mm (0.16 inch)) in the adjusting hole of the oil pump driven sprocket to temporarily lock the sprocket in position. Remove the nut.

(c) Remove the bolt, chain tensioner plate and spring.
(d) Remove the chain tensioner, oil pump driven sprocket and chain.

INSTALLATION

1. INSTALL NO.2 CHAIN SUB-ASSEMBLY
(a) Set the crankshaft key into the left horizontal position.
(b) Turn the cutout of the oil pump drive shaft to the top.

(c) Align the mark links (yellow colored links) with the timing marks of the sprocket as shown in the illustration.
(d) Insert the sprockets with chain to the crankshaft and oil pump shaft.
(e) Temporarily tighten the oil pump driven sprocket with the nut.

(f) Insert the damper spring into the adjusting hole, and install the chain tensioner plate with the bolt.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)

(g) Align the adjusting hole of the oil pump driven sprocket with the groove of the oil pump.
(h) Put a bar ([diameter]4 mm (0.16 inch)) in the adjusting hole of the oil pump driven sprocket to temporarily lock the sprocket in position. Install the nut.
Torque: 30 Nm (301 kgf-cm, 22 ft. lbs.)

(i) Rotate the crankshaft counterclockwise by 90°, and align the crankshaft key to the top.

2. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
(a) Install the crankshaft timing sprocket.

3. INSTALL CHAIN VIBRATION DAMPER NO.1
(a) Install the chain vibration damper with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

4. INSTALL CHAIN SUB-ASSEMBLY
(a) Set the No.1 cylinder to TDC/compression.
(1) Align the timing marks of the camshaft timing gear/sprocket and bearing caps (No. 1 and No. 2).

(2) Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward.

(b) Align the mark link (gold or orange colored link) with the timing mark of the crankshaft timing sprocket.

(d) Align the mark links (gold or yellow colored links) with the timing marks of the camshaft timing gear and camshaft timing sprocket. Install the chain.

5. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper with the bolt.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)

6. INSTALL TIMING CHAIN GUIDE
(a) Install the timing chain guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

7. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
(a) Install the sensor plate with the F mark facing forward.
8. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

9. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(a) Install the V-ribbed belt tensioner to the engine by first tightening the bolt and then tightening the nut.
Torque: 60 Nm (607 kgf-cm, 44 ft. lbs.)

NOTICE: When replacing the V-ribbed belt tensioner with a new one, do not pull out the pin.

10. INSTALL ENGINE MOUNTING BRACKET RH
(a) Install the engine mounting bracket with the 3 bolts.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)

11. INSTALL ENGINE MOUNTING INSULATOR
(a) Raise the engine and install the engine mounting insulator RH.
(b) Install the engine mounting insulator RH with the 4 nuts.
Torque:
Nut A 95 Nm (969 kgf-cm, 70 ft. lbs.)
Nut B 87 Nm (888 kgf-cm, 64 ft. lbs.)

(d) Install the engine mounting insulator FR with the bolt.
Torque: 87 Nm (888 kgf-cm, 64 ft. lbs.)

(e) M/T:
Install the engine lateral control rod with the bolt.
Torque: 89 Nm (910 kgf-cm, 66 ft. lbs.)

12. INSTALL OIL PAN SUB-ASSEMBLY
(a) Remove any old packing material and be careful not to drop any oil on the contact surface of the cylinder block and oil pan.
(b) Apply seal packing in a continuous bead (diameter: 4 to 4.5 mm (0.16 to 0.18 inch)) as shown in the illustration, and install the oil pan.
Seal packing: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil pan within 3 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing.

(c) Install the oil pan with the 12 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
13. INSTALL NO.1 CHAIN TENSIONER ASSEMBLY

14. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install the sensor with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
(b) Confirm that the wire harness of the sensor is placed as shown in the illustration.

15. INSTALL CRANKSHAFT PULLEY
(a) Install the crankshaft pulley.
(1) Align the pulley set key with the key groove of the pulley, and side on the pulley.
(2) Using SST, install the pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 170 Nm (1,733 kgf-cm, 125 ft. lbs.)

(b) Turn the crankshaft counterclockwise and disconnect the plunger knock pin from the hook.

(c) Turn the crankshaft clockwise and check that the slipper is pushed by the plunger.
16. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
17. INSTALL IGNITION COIL ASSEMBLY
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
18. INSTALL VANE PUMP ASSEMBLY
19. INSTALL GENERATOR ASSEMBLY
20. INSTALL ENGINE WIRE
21. INSTALL FAN AND GENERATOR V BELT

(a) When reusing the V-ribbed belt tensioner assembly:
(1) Using SST, slowly turn the V-ribbed belt tensioner clockwise and install the V belt.
SST 09249-63010

NOTICE:
^ Make sure that SST and other tools are set to the tensioner securely.
^ When compressing the V-ribbed belt tensioner, slowly turn the tensioner.

(b) When replacing the V-ribbed belt tensioner clockwise with a new one:
(1) Using SST, slowly turn the V-ribbed belt tensioner clockwise and install the V belt.

(2) Pull out the pin with the V-ribbed belt tensioner being compressed in a clockwise direction.
SST 09249-63010
(3) Slowly return the V-ribbed belt tensioner.

NOTICE:
^ Make sure that SST and other tools are set to the tensioner securely.
^ When compressing the V-ribbed belt tensioner, slowly turn the tensioner.

22. INSTALL ENGINE MOUNTING BRACKET NO.2 RH
Torque: 52 Nm (531 kgf-cm, 38 ft. lbs.)
23. INSTALL ENGINE MOUNTING STAY NO.2 RH
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)

24. INSTALL ENGINE MOVING CONTROL ROD W/ BRACKET
(a) Install the engine mounting control rod with the 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
25. INSTALL FRONT EXHAUST PIPE ASSEMBLY
26. INSTALL FRONT WHEEL RH
27. INSTALL HOOD SUB-ASSEMBLY
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
28. ADD ENGINE OIL
29. INSPECT FOR ENGINE OIL LEAKS