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Chain Sub-ASSY: Replacement

  1. REMOVE FRONT WHEEL RH 
  2. REMOVE CYLINDER HEAD COVER NO. 2 
    1. Remove the 4 nuts and the cylinder head cover No. 2.
      Fig 1: Removing Nuts Of Cylinder Head Cover No. 2
      G00756046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE IGNITION COIL NO. 1 
    1. Remove the 4 bolts and pull out the 4 ignition coils.
      Fig 2: Removing Ignition Coil Bolts
      G00756047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. DISCONNECT VENTILATION HOSE 
    1. Disconnect the ventilation hose from the cylinder head cover.
      Fig 3: Disconnecting Ventilation Hose From Cylinder Head Cover
      G00756048Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. DISCONNECT VENTILATION HOSE NO. 2 
    1. Disconnect the ventilation hose NO. 2 from the cylinder head cover.
      Fig 4: Disconnecting Ventilation Hose No. 2 From Cylinder Head Cover
      G00756049Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE CYLINDER HEAD COVER SUB-ASSY 
    1. Remove the 9 bolts, the 2 nuts and the cylinder head cover.
      Fig 5: Removing Bolts And Nuts Of Cylinder Head Cover
      G00756050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE FAN AND GENERATOR V BELT (See  DRIVE BELT  ) 
  8. REMOVE GENERATOR ASSY (See  GENERATOR  ) 
  9. REMOVE ENGINE UNDER COVER RH 
  10. DRAIN ENGINE OIL 
  11. DRAIN ENGINE COOLANT (See  ENGINE COOLANT  ) 
  12. REMOVE VANE PUMP V BELT (See  DRIVE BELT  ) 
  13. REMOVE WATER PUMP PULLEY 
  14. REMOVE WATER PUMP ASSY (See  WATER PUMP ASSY  ) 
  15. REMOVE CRANKSHAFT DAMPER SUB-ASSY 
    1. Set the No. 1 cylinder to the TDC/compression.
      1. Turn the crankshaft damper, and align its timing notch with timing mark "0" of the chain cover.
      2. Check that both timing marks on the camshaft timing sprocket and the camshaft timing gear are facing upward as shown in the illustration.
      Fig 6: Aligning Camshaft Timing Notch With Timing Mark "0" Of Chain Cover
      G00756051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

    2. Using SST, remove the pulley bolt.

      SST 09213-58012 (91111-50845), 09330-00021

      Fig 7: Removing Chain Pulley Bolt And Damper
      G00756052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT: 

    If necessary, remove the damper with SST.

    SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)

  16. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY 
    1. Disconnect the oil control valve connector.
    2. Remove the bolt, oil control valve and the O-ring.
      Fig 8: Disconnecting Oil Control Valve Connector
      G00756053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE CRANKSHAFT POSITION SENSOR (See  CRANKSHAFT POSITION SENSOR  ) 
  18. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSY RH 
    1. Place a wooden block on a jack underneath the engine.
      Fig 9: Placing A Wooden Block On A Jack Underneath The Engine
      G00756054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt which is used to fix the liquid tube to the engine mounting insulator RH.
    3. Remove the 5 bolts, the nut and the engine mounting insulator RH.
      Fig 10: Removing Nuts And Bolts Of Engine Mounting Insulator (RH)
      G00756055Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE ENGINE MOUNTING BRACKET RH 
    1. Remove the 4 bolts and the engine mounting bracket RH.
      Fig 11: Removing Nuts And Bolts Of Engine Mounting Bracket (RH)
      G00756056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE OIL PUMP ASSY (See  OIL PUMP ASSY  ) 
  21. REMOVE OIL PUMP SEAL (See  OIL PUMP SEAL  ) 
  22. REMOVE CHAIN TENSIONER ASSY NO. 1 
    NOTE:
    • Do not 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.
    1. While rotating the stopper plate of the chain tensioner upward as shown in the illustration push in the plunger of the tensioner.
    2. While rotating the stopper plate of the tensioner down-ward, insert a 2.5 mm (0.098 in.) diameter bar into the holes of the stopper plate and the tensioner to hold the stopper plate.
      Fig 12: Rotating Stopper Plate Of Chain Tensioner Upward And Pushing In The Plunger Of Tensioner
      G00756057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE CHAIN TENSIONER SLIPPER 
    1. Remove the bolt and the chain tensioner slipper.
  24. REMOVE CHAIN VIBRATION DAMPER NO. 1 
    1. Remove the 2 bolts and the chain vibration damper.
  25. REMOVE CHAIN SUB-ASSY 
  26. INSTALL CHAIN SUB-ASSY 
    1. After setting the crankshaft at ATDC 40 to 140°, set cams of intake and exhaust timing sprockets at ATDC 20° and then reset the crankshaft at ATDC 20°.
    2. Install the chain vibration damper with the 2 bolts.

      Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) 

    3. Align the matchmarks of the camshaft timing sprocket, the camshaft timing gear and the crankshaft timing sprocket with each mark plate (colored in yellow) of the timing chain.

      HINT: 

      To prevent the exhaust camshaft from spring back, turn it using a wrench and set it at the mark on the chain.

    4. Install the chain tensioner slipper with the bolt.

      Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) 

    5. Install the chain tensioner with the 2 bolts.

      Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) 

    6. Remove the bar from the chain tensioner.
    7. Check the tension between the intake and exhaust camshaft timing sprocket.
      Fig 13: Aligning Matchmarks Of Camshaft Timing Sprocket, The Camshaft Timing Gear And The Crankshaft Timing Sprocket With Each Mark Plate Of Timing Chain
      G00756058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL OIL PUMP SEAL (See  OIL PUMP SEAL  ) 

    SST 09950-60010 (09951-00250, 09951-00380, 09952-06010), 09950-70010 (09951-07100)

  28. INSTALL OIL PUMP ASSY (See  OIL PUMP ASSY  ) 
  29. INSTALL WATER PUMP ASSY (See  WATER PUMP ASSY  ) 
  30. INSTALL ENGINE MOUNTING BRACKET RH 
    1. Install the engine mounting bracket RH with the 4 bolts.

      Torque: 55 N.m (561 kgf.cm, 41 ft.lbf) 

      Fig 14: Installing Bolts Of Engine Mounting Bracket RH
      G00756059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSY RH 
    1. Install the RH engine mounting insulator with the 5 bolts and the nut.

      Torque: 

      Bolt A 45 N.m (459 kgf.cm, 33 ft.lbf) 

      Bolt B 52 N.m (530 kgf.cm, 38 ft.lbf) 

      Nut 52 N.m (530 kgf.cm, 38 ft.lbf) 

    2. Install the liquid tube with the bolt.

      Torque: 

      Bolt C 9.8 N.m (100 kgf.cm, 7.2 ft.lbf) 

      Fig 15: Identifying RH Engine Mounting Insulator Bolts
      G00756060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY 
    1. Apply a light coat of a new O-ring, and install it to the camshaft timing oil control valve.
    2. Install the camshaft timing oil control valve with the bolt.

      Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf) 

    NOTE: Be careful not to twist an O-ring.
  33. INSTALL CRANKSHAFT POSITION SENSOR (See  CRANKSHAFT POSITION SENSOR  ) 
  34. INSTALL WATER PUMP PULLEY (See  WATER PUMP ASSY  ) 

    SST 09960-10010 (09962-01000, 09963-00600)

  35. INSTALL CRANKSHAFT DAMPER SUB-ASSY 
    1. Align the pin hole of the crankshaft damper with the pin position and install the crankshaft damper.
    2. Using SST, install the pulley bolt.

      SST 09330-00021, 09213-58012 (91111-50845)

      Torque: 128 N.m (1,305 kgf.cm, 95 ft.lbf) 

      Fig 16: Installing Pulley Bolt
      G00756061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL CYLINDER HEAD COVER SUB-ASSY 
    1. Apply seal packing to the 2 locations shown in the illustration.

      Seal packing: Part No. 08826 - 00080 or equivalent 

      NOTE:
      • 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 installation.
      Fig 17: Identifying Locations Of Seal Packing
      G00756062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the cylinder head cover with the 9 bolts, the 2 seal washers and the 2 nuts.
    3. Using several steps, tighten the bolts and the nuts uniformly in the sequence shown in the illustration.

      Torque: 10 N.m (102 kgf.cm, 7.4 ft.lbf) 

  37. INSTALL IGNITION COIL NO. 1 

    Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) 

    Fig 18: Tightening Sequence Of Cylinder Head Cover Bolts And Nuts
    G00756063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL CYLINDER HEAD COVER NO. 2 
    1. First tighten nut A, then tighten bolt B.

      Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf) 

      Fig 19: Identifying Nuts Of Cylinder Head Cover No. 2
      G00756064Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL GENERATOR ASSY (See  GENERATOR  ) 
  40. INSTALL VANE PUMP V BELT 
    1. Temporarily install the V-ribbed belt on each pulley.
  41. INSTALL FAN AND GENERATOR V BELT 
    1. Temporarily install the V-ribbed belt on each pulley.
  42. ADJUST FAN AND GENERATOR V BELT (See  DRIVE BELT  ) 
  43. ADJUST VANE PUMP V BELT (See  DRIVE BELT  ) 
  44. INSPECT DRIVE BELT DEFLECTION AND TENSION (See  INSPECTION  ) 
  45. INSTALL OIL PAN DRAIN PLUG 
    1. Install the drain plug with a new gasket.

      Torque: 38 N.m (382 kgf.cm, 28 ft.lbf) 

  46. ADD ENGINE OIL 
  47. CHECK FOR ENGINE OIL LEAKS 
  48. ADD ENGINE COOLANT (See  ENGINE COOLANT  ) 
  49. CHECK FOR ENGINE COOLANT LEAKS (See  COOLING SYSTEM  ) 
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