Timing Chain: Service and Repair
TIMING CHAINTiming Chain Components (Part 1):
Timing Chain Components (Part 2):
Timing Chain Components (Part 3):
Timing Chain Components (Part 4):
Timing Chain Components (Part 5):
REMOVAL
1. REMOVE REAR NO. 2 FLOOR BOARD
2. REMOVE REAR DECK FLOOR BOX
3. REMOVE REAR NO. 3 FLOOR BOARD
4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
5. REMOVE RADIATOR SUPPORT OPENING COVER
6. REMOVE FRONT WHEELS
7. REMOVE NO. 3 ENGINE UNDER COVER
8. REMOVE NO. 4 CENTER ENGINE UNDER COVER
9. DRAIN ENGINE COOLANT
10. DRAIN ENGINE OIL
11. REMOVE WIPER ARM HEAD CAP
12. REMOVE FRONT WIPER ARM LH
13. REMOVE FRONT WIPER ARM RH
14. REMOVE HOOD TO COWL TOP SEAL
15. REMOVE COWL TOP VENTILATOR LOUVER LH
16. REMOVE COWL TOP VENTILATOR LOUVER RH
17. REMOVE WINDSHIELD MOTOR WITH WIPER LINK ASSEMBLY
18. REMOVE FRONT COWL TOP PANEL OUTER
19. REMOVE AIR CLEANER ASSEMBLY
a. Loosen the clamp, then disconnect the No. 1 air cleaner inlet from the air cleaner case.
b. Disconnect the intake air flow meter connector, then remove the wire harness clamp.
c. Loosen the clamp, then remove the 2 bolts and air cleaner assembly
20. REMOVE NO. 2 AIR CLEANER INLET
a. Remove the clip and No. 2 air cleaner inlet.
21. DISCONNECT BRAKE MASTER CYLINDER RESERVOIR
a. Disconnect the connector.
b. Remove the 2 bolts.
c. Separate the claw fitting, then suspend the brake master cylinder reservoir with rope.
NOTICE: Be careful of the angle of the brake master cylinder reservoir when suspending to prevent air from coming into the hose.
22. REMOVE RESERVOIR BRACKET
a. Disconnect the hose from the brake master cylinder reservoir bracket.
b. Remove the 3 bolts and wire harness clamp, then remove the brake master cylinder reservoir bracket.
23. REMOVE WINDSHIELD WASHER JAR ASSEMBLY
a. Loosen the bolt which holds the headlight RH.
b. Disconnect the connector and remove the wire harness clamp.
c. Remove the bolt and bracket.
d. Remove the nut.
e. Slightly lift the headlight RH and separate the claw fitting, then remove the washer jar assembly.
f. Disconnect the hose from the washer jar assembly.
24. REMOVE CYLINDER HEAD COVER
a. Disconnect the fuel injector connector and ignition coil connector.
b. Remove the 3 bolts and wire harness clamp, then disconnect the wire harness.
c. Remove the brake master cylinder reservoir cover.
d. Disconnect the ventilation hose and ventilation hose No. 2.
e. Remove the bolt and ignition coil.
f. Remove the 9 bolts and 2 nuts, then remove the cylinder head cover.
25. REMOVE PURGE VSV
a. Disconnect the connector and hose.
b. Remove the bolt and purge VSV.
26. REMOVE DRIVE BELT
27. REMOVE WATER PUMP
28. REMOVE CRANKSHAFT PULLEY
a. Using SST, hold the crankshaft pulley and loosen the crankshaft bolt.
SST 09213-58013 (91111-50845), 09330-00021
NOTICE: When installing SST, be careful that the bolt which holds SST does not interfere with the chain cover.
b. Loosen the crankshaft bolt until 2 to 3 threads of the bolt are tightened to the crankshaft.
c. Using SST, remove the crankshaft damper.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
d. Remove the crankshaft bolt.
29. REMOVE ENGINE MOUNTING INSULATOR RH
a. Put a wooden block on a jack. Support the oil pan with the jack.
b. Remove the 3 bolts and 4 nuts, then remove the engine mounting insulator RH.
30. REMOVE ENGINE MOUNTING SPACER
a. Remove the 2 bolts and engine mounting spacer.
31. REMOVE ENGINE MOUNTING BRACKET
a. Remove the 4 bolts and engine mounting bracket.
32. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
a. Disconnect the connector.
b. Remove the bolt and camshaft timing oil control valve assembly
33. REMOVE CRANKSHAFT POSITION SENSOR
34. REMOVE TIMING CHAIN COVER
35. REMOVE OIL PUMP SEAL
36. SET NO. 1 CYLINDER TO TDC / COMPRESSION
a. Install the washer to the crankshaft bolt, then install the bolt to the crankshaft.
b. Turn the crankshaft clockwise so it is positioned as illustrated.
37. REMOVE NO. 1 CHAIN TENSIONER
a. Lift up the stopper plate, then unlock the plunger.
b. Push in the plunger to the end with the plunger unlocked.
c. Lower the stopper plate with the plunger pushed to the end, then lock the plunger.
d. Insert a 3.0 mm (0.118 inch) diameter bar into the hole of the stopper plate with the plunger locked.
HINT: If the stopper plate is not completely lowered and a 3.0 mm (0.118 inch) diameter bar cannot be inserted, unlock and pull out the plunger slightly. Then the stopper plate will be completely lowered and a 3.0 mm (0.118 inch) diameter bar can be inserted easily.
e. Remove the 2 bolts and chain tensioner.
38. REMOVE CHAIN TENSIONER SLIPPER
a. Remove the bolt and tensioner slipper.
39. REMOVE NO. 1 CHAIN VIBRATION DAMPER
a. Remove the 2 bolts and chain vibration damper.
40. REMOVE CHAIN
a. Remove the chain from the engine.
INSTALLATION
1. INSTALL CHAIN
a. Set the position of the No. 1 cylinder to 20° ATDC.
NOTICE: To prevent the pistons from hitting against valves, the following procedures must be performed in this order:
1. Set the crankshaft between 40 to 140° ATDC.
2. Set the cams of the intake and exhaust timing sprockets to 20° ATDC.
3. Reset the crankshaft to 20° ATDC.
b. Install the chain vibration damper with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
c. Align the timing marks of the camshaft timing sprocket, camshaft timing gear and crankshaft timing sprocket with each mark plate (colored in yellow) of the timing chain.
HINT: To prevent the exhaust camshaft from springing back, turn it using a wrench and set it at the mark on the chain.
d. Install the chain tensioner slipper with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
e. Install the chain tensioner with the 2 bolts.
1. Lift up the stopper plate, then unlock the plunger.
2. Push in the plunger to the end with the plunger unlocked.
3. Lower the stopper plate with the plunger pushed to the end, then lock the plunger.
4. Insert a 3.0 mm (0.118 inch) diameter bar into the hole of the stopper plate with the plunger locked.
HINT: If the stopper plate is not completely lowered and a 3.0 mm (0.118 inch) diameter bar cannot be inserted, unlock and pull out the plunger slightly. Then the stopper plate will be completely lowered and a 3.0 mm (0.118 inch) diameter bar can be inserted easily
5. Install the chain tensioner with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
6. Remove the bar from the chain tensioner.
f. Check the tension between the intake and exhaust camshaft timing sprockets.
2. INSTALL OIL PUMP SEAL
3. INSTALL TIMING CHAIN COVER
4. INSTALL CRANKSHAFT POSITION SENSOR
5. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
6. INSTALL ENGINE MOUNTING BRACKET
a. Install the engine mounting bracket with the 4 bolts.
Torque: 55 Nm (561 kgf-cm, 41 ft. lbs.)
7. INSTALL ENGINE MOUNTING SPACER
a. Install the engine mounting spacer with the 2 bolts.
Torque: 55 Nm (561 kgf-cm, 41 ft. lbs.)
8. INSTALL ENGINE MOUNTING INSULATOR RH
a. Install the engine mounting insulator RH with the 3 bolts and 4 nuts.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)
9. INSTALL CRANKSHAFT PULLEY
a. Align the hole of the crankshaft damper with the straight pin, then install the crankshaft damper.
b. Using SST, hold the crankshaft damper and tighten the crankshaft bolt.
SST 09213-58013 (91111-50845), 09330-00021
Torque: 128 Nm (1,305 kgf-cm, 95 ft. lbs.)
NOTICE: When installing SST, be careful that the bolt which holds SST does not interfere with the chain cover.
10. INSTALL WATER PUMP
11. INSTALL DRIVE BELT
12. CHECK DRIVE BELT TENSION
13. INSTALL PURGE VSV
a. Install the purge VSV with the bolt.
b. Connect the hose and connector.
14. INSTALL CYLINDER HEAD COVER
a. Apply seal packing to the 2 locations shown in the illustration, then install the cylinder head cover.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent
NOTICE:
^ Remove any oil from the contact surface.
^ Install the cylinder head cover within 3 minutes after applying seal packing.
^ Do not start the engine within 2 hours of installing.
b. Install the cylinder head cover with the 9 bolts and 2 nuts.
c. Using several steps, tighten the bolts and nuts to the specified torque in the sequence shown in the illustration.
Torque: 10 Nm (102 kgf-cm, 74 inch lbs.)
d. Install the ignition coil with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
e. Install the brake master cylinder reservoir cover to the cylinder head cover.
f. Install the wire harness and brake master cylinder reservoir cover with the 3 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
g. Connect the fuel injector connector and ignition coil connector.
15. INSTALL WINDSHIELD WASHER JAR
a. Install the windshield washer with the 2 bolts and nut.
Torque:
4.9 Nm (50 kgf-cm, 43 inch lbs.) for bolt A
14 Nm (143 kgf-cm, 10 ft. lbs.) for bolt B
5.5 Nm (56 kgf-cm, 49 inch lbs.) for nut
b. Connect the 2 connectors and wire harness.
16. INSTALL RESERVOIR BRACKET
a. Install the reservoir bracket with the 3 bolts and connect the wire harness clamp.
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)
17. INSTALL BRAKE MASTER CYLINDER RESERVOIR
a. Attach the claw and install the master cylinder reservoir with the 2 bolts.
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)
b. Connect the connector.
18. INSTALL NO. 2 AIR CLEANER INLET
19. INSTALL AIR CLEANER ASSEMBLY
a. Install the air cleaner with the 2 bolts and tighten the clamp.
Torque:
7.0 Nm (71 kgf-cm, 62 inch lbs.) for bolt
3.0 Nm (31 kgf-cm, 27 inch lbs.) for clamp
b. Connect the MAF meter connector and clamp.
c. Connect the No. 1 air inlet, and then tighten the clamp.
20. INSTALL FRONT COWL TOP PANEL OUTER
21. INSTALL WINDSHIELD WIPER MOTOR AND WIPER LINK ASSEMBLY
22. INSTALL COWL TOP VENTILATOR LOUVER RH
23. INSTALL COWL TOP VENTILATOR LOUVER LH
24. INSTALL HOOD TO COWL TOP SEAL
25. INSTALL FRONT WIPER ARM LH
26. INSTALL FRONT WIPER ARM RH
27. INSTALL WIPER ARM HEAD CAP
28. ADD ENGINE OIL
29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
30. INSTALL REAR NO. 3 FLOOR BOARD
31. INSTALL REAR DECK FLOOR BOARD
32. INSTALL REAR NO. 2 FLOOR BOARD
33. ADD ENGINE COOLANT
34. CHECK FOR ENGINE COOLANT LEAKS
35. INSTALL RADIATOR SUPPORT OPENING COVER
36. INSTALL NO. 4 CENTER ENGINE UNDER COVER
37. INSTALL NO. 3 ENGINE UNDER COVER
38. INSTALL FRONT WHEELS
39. PERFORM INITIALIZATION
NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.