Replacement

TIMING CHAIN OR BELT COVER SUB-ASSEMBLY (1GR-FE(2WD)
































COMPONENTS

REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE
2. REMOVE BATTERY
3. DRAIN ENGINE COOLANT
4. DRAIN ENGINE OIL
5. REMOVE ENGINE ASSEMBLY
6. REMOVE OIL LEVEL GAUGE GUIDE
7. REMOVE WATER INLET
8. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
9. REMOVE IDLER PULLEY SUB-ASSEMBLY NO.2
10. REMOVE IDLER PULLEY SUB-ASSEMBLY NO.1
11. REMOVE CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05030)
12. REMOVE OIL PAN SUB-ASSEMBLY NO.2
SST 09032-00100
13. REMOVE OIL STRAINER SUB-ASSEMBLY
14. REMOVE OIL PAN SUB-ASSEMBLY
15. REMOVE IGNITION COIL ASSEMBLY
16. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
18. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
19. REMOVE WT SENSOR
20. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY
a. Remove the 3 bolts, 2 nuts, oil filter bracket and gasket.





21. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
a. Remove the 24 bolts and 2 nuts.





b. Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver.

NOTICE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder block and cylinder head.

c. Remove the O-ring from the LH cylinder head.
22. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
23. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
SST 09226-10010
24. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
a. Remove any old packing (FIPG) material. Be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.





b. Install a new O-ring onto the LH cylinder head as shown in the illustration.





c. Apply continuous beads of seal packing (diameter 3 to 4 mm (0.12 to 0.16 inch)) to the 4 locations shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent





d. Apply continuous beads of seal packing (diameter 3 to 4 mm (0.12 to 0.16 inch)) to the timing chain cover as shown in the illustration.
Seal packing: Water pump part: Part No.08826-00100 or equivalent Other parts: Part No.08826-00080 or equivalent

NOTICE:
- Install the timing chain cover within 3 minutes of applying the seal packing. Timing chain cover bolts and nuts must be tightened within 15 minutes of installation. Otherwise, the seal packing must be removed and reapplied.
- Do not apply seal packing to portion A shown in the illustration.





e. Align the key way of the oil pump drive rotor with the rectangular portion of the crankshaft timing gear, and slide the timing chain cover into place.





f. Install the timing chain cover with the 24 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque: 23 Nm (235 kgf-cm, 17 ft. lbs.)

NOTICE: Pay attention not to wrap the chain and slipper over the timing chain cover seal line.





HINT: Each bolt length is as above.

25. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY
a. Install a new gasket and the oil filter bracket with the 3 bolts and 2 nuts.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
26. INSTALL WT SENSOR
27. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
28. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
29. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
30. INSTALL IGNITION COIL ASSEMBLY
31. INSTALL OIL PAN SUB-ASSEMBLY
32. INSTALL OIL STRAINER SUB-ASSEMBLY
33. INSTALL OIL PAN SUB-ASSEMBLY NO.2
34. INSTALL CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021
35. INSTALL IDLER PULLEY SUB-ASSEMBLY NO.1
36. INSTALL IDLER PULLEY SUB-ASSEMBLY NO.2
37. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
38. INSTALL WATER INLET
39. INSTALL OIL LEVEL GAUGE GUIDE
40. INSTALL ENGINE ASSEMBLY
41. INSTALL BATTERY
42. ADD ENGINE COOLANT
43. ADD ENGINE OIL
44. CHECK FOR ENGINE COOLANT LEAKAGE
45. CHECK FOR ENGINE OIL LEAKAGE
46. CHECK FOR FUEL LEAKAGE
47. CHECK FOR EXHAUST GAS LEAKAGE
48. INSPECT IGNITION TIMING
SST 09843-18040
49. INSPECT ENGINE IDLING SPEED
SST 09843-18030
50. INSPECT CO/HC