Timing Chain: Service and Repair

TIMING CHAIN

COMPONENTS:

REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY
3. REMOVE FRONT WHEEL RH
4. REMOVE ENGINE UNDER COVER LH
5. REMOVE ENGINE UNDER COVER RH
6. REMOVE FRONT FENDER APRON SEAL RH
7. DRAIN ENGINE OIL
8. REMOVE FRONT EXHAUST PIPE ASSEMBLY
9. REMOVE NO. 2 ENGINE MOUNTING STAY RH
10. REMOVE ENGINE MOVING CONTROL ROD SUB-ASSEMBLY
11. REMOVE NO. 2 ENGINE MOUNTING BRACKET RH
12. REMOVE V-RIBBED BELT
13. REMOVE GENERATOR ASSEMBLY
14. REMOVE VANE PUMP ASSEMBLY
15. REMOVE IGNITION COIL ASSEMBLY
16. DISCONNECT VENTILATION HOSE
17. DISCONNECT NO. 2 VENTILATION HOSE

18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Remove the 2 bolts and disconnect the 2 engine wires.

(b) Remove the 8 bolts, 2 nuts, and the cylinder head cover.
19. SET NO. 1 CYLINDER TO TDC/COMPRESSION
20. REMOVE CRANKSHAFT PULLEY
21. REMOVE CRANK POSITION SENSOR

22. 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 surfaces of the crankcase, chain cover and oil pan.

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

NOTICE: Do not turn the crankshaft without the chain tensioner.

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

Parts No.:

Torque: 38 Nm (387 kgf-cm, 28 ft. lbs.)
(b) Attach the sling device to the engine hangers and chain block.
25. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(a) Lift the engine upward using the chain block.

NOTICE: Do not lift the engine more than necessary.

(b) Remove the bolt, nut and V-ribbed belt tensioner.

26. 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 2 bolts and disconnect the steering gear return tube clamps 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.

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

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

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

32. REMOVE NO. 1 CHAIN VIBRATION DAMPER
(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 SPROCKET
(a) Remove the crankshaft timing sprocket.

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

(b) Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft sprocket to lock the gear in position, and then remove the nut.

(d) Remove the chain tensioner, oil pump driven sprocket and chain.

INSPECTION
1. INSPECT CHAIN SUB-ASSEMBLY
2. INSPECT NO. 2 CHAIN SUB-ASSEMBLY
3. INSPECT OIL PUMP DRIVE SPROCKET
4. INSPECT OIL PUMP DRIVE SHAFT SPROCKET
5. INSPECT CHAIN TENSIONER SLIPPER
6. INSPECT NO. 1 CHAIN VIBRATION DAMPER
7. INSPECT CHAIN TENSIONER PLATE
8. INSPECT NO. 1 CHAIN TENSIONER

INSTALLATION

1. INSTALL NO. 2 CHAIN SUB-ASSEMBLY
(a) Set the crankshaft key into the left horizontal position.
(b) Turn the drive shaft so that the cutout faces upward.

(c) Align the yellow mark links with the timing marks of each gear as shown in the illustration.
(d) Install the sprockets onto the crankshaft and oil pump shaft with the chain wrapped on the gears.
(e) Temporarily tighten the oil pump drive shaft sprocket with the nut.

(f) Insert the damper spring into the adjusting hole, and then 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 drive shaft sprocket with the groove of the oil pump.
(h) Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, and then tighten the nut.
Torque: 30 Nm (301 kgf-cm, 22 ft. lbs.)

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

2. INSTALL CRANKSHAFT TIMING SPROCKET
(a) Install the crankshaft timing sprocket.

3. INSTALL NO. 1 CHAIN VIBRATION DAMPER
(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) Turn the camshafts with a wrench (using the hexagonal lobe) to align the timing marks of the camshaft timing gear with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration.

(2) Using the crankshaft pulley bolt, turn the crankshaft to position with the key on the crankshaft upward.

(b) Install the chain onto the crankshaft timing sprocket with the gold or pink mark link aligned with the timing mark on the crankshaft.

(d) Align the gold or yellow link with each timing mark located on the camshaft timing gear and sprocket, then 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 NO. 1 CRANKSHAFT POSITION SENSOR PLATE
(a) Install the sensor plate with the "F" mark facing forward.
8. INSTALL TIMING CHAIN CASE OIL SEAL
9. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

10. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(a) Install the V-ribbed belt tensioner with the bolt and nut.
Torque: 60 Nm (607 kgf-cm, 44 ft. lbs.)

NOTICE: Do not lift the engine more than necessary.

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

12. 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.)

(c) Install the steering gear return tube clamps to the frame with the 2 bolts.
Torque: 8.0 Nm (80 kgf-cm, 69 inch 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.)

13. INSTALL OIL PAN SUB-ASSEMBLY
(a) Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.
(b) Apply a continuous bead of seal packing (Diameter 3.0 to 4.0 mm (0.118 to 0.157 inch)) as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Block, Three Bond 1207B or Equivalent

NOTICE:
- Remove any oil from the contact surfaces.
- 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 to the cylinder block.

(d) Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
14. INSTALL CRANK POSITION SENSOR
15. INSTALL CRANKSHAFT PULLEY

16. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
(a) Release the ratchet pawl, then fully push in the plunger and hook the hook to the pin so that the plunger is in the position shown in the illustration.

(b) Install a new gasket and the chain tensioner with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

NOTICE: If the hook releases the plunger while the chain tensioner is being installed, set the hook again.

(d) Turn the crankshaft clockwise, then check that the plunger is extended.
17. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Remove any old packing material from the contact surface.

(b) Apply seal packing to the 2 locations shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Block, Three Bond 1207B or Equivalent

NOTICE:
- Remove any oil from the contact surface.
- Install the cylinder head cover within 3 minutes of applying seal packing.
- Do not add engine oil for at least 2 hours after installing the cylinder head cover.

(c) Install the cylinder head cover with the 8 bolts and 2 nuts.
Torque:
Bolt A 11 Nm (112 kgf-cm, 8 ft. lbs.)
Bolt B 14 Nm (143 kgf-cm, 10 ft. lbs.)
Nut 11 Nm (112 kgf-cm, 8 ft. lbs.)

(d) Install the 2 engine wires with the 2 bolts.
Torque: 8.4 Nm (86 kgf-cm, 74 inch lbs.)
18. INSTALL NO. 2 VENTILATION HOSE
19. INSTALL VENTILATION HOSE
20. INSTALL IGNITION COIL ASSEMBLY
(a) Install the 4 ignition coils with the 4 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
21. INSTALL VANE PUMP ASSEMBLY
22. INSTALL GENERATOR ASSEMBLY
23. INSTALL V-RIBBED BELT
24. INSTALL NO. 2 ENGINE MOUNTING BRACKET RH
25. INSTALL ENGINE MOVING CONTROL ROD SUB-ASSEMBLY
26. INSTALL NO. 2 ENGINE MOUNTING STAY RH
27. INSTALL FRONT EXHAUST PIPE ASSEMBLY
28. ADD ENGINE OIL
29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
30. CHECK FOR ENGINE OIL LEAKS
31. CHECK FOR EXHAUST GAS LEAKS
32. CHECK IGNITION TIMING
33. INSTALL FRONT FENDER APRON SEAL RH
34. INSTALL ENGINE UNDER COVER LH
35. INSTALL ENGINE UNDER COVER RH
36. INSTALL FRONT WHEEL RH
37. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY