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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 cylinder head cover No. 2.
      Fig 1: Removing Cylinder Head Cover
      G00759048Courtesy 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
      G00759049Courtesy 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
      G00759050Courtesy 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
      G00759051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE CYLINDER HEAD COVER SUB-ASSY 
    1. Remove the 9 bolts and 2 nuts, and then remove the cylinder head cover.
      Fig 5: Removing Cylinder Head Cover Sub Assembly
      G00759052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE FAN AND GENERATOR V BELT (See  DRIVE BELT  ) 
  8. REMOVE GENERATOR ASSY (See  GENERATORS & REGULATORS  ) 
  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 (See  WATER PUMP  ) 
  14. REMOVE WATER PUMP ASSY (See  WATER PUMP  ) 
  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 the timing mark "0" of the chain cover.
      2. Check that both timing marks on the camshaft timing sprocket and camshaft timing gear are facing upward as shown in the illustration.

      HINT: 

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

      Fig 6: Removing Crankshaft Damper Sub Assembly
      G00759053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the pulley bolt.

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

      HINT: 

      If necessary, remove the damper with SST.

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

      Fig 7: Removing Pulley Bolt And Damper With SST Tools
      G00759054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY 
    1. Disconnect the oil control valve connector.
    2. Remove the bolt, oil control valve and O-ring
  17. REMOVE CRANKSHAFT POSITION SENSOR (See  CRANKSHAFT POSITION SENSOR  ) 
    Fig 8: Removing Camshaft Timing Oil Control Valve Assy
    G00759055Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSY RH 
    1. Place a wooden block on a jack underneath the engine.
      Fig 9: Removing Procedure Of Engine Mounting Insulator
      G00759056Courtesy 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 nut, and then remove the engine mounting insulator RH.
      Fig 10: Locating Engine Mounting Insulator Bolt
      G00759057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE TRANSVERSE ENGINE MOUNTING BRACKET 
    1. Remove the 4 bolts and engine mounting bracket RH.
      Fig 11: Removing Transverse Engine Mounting Bracket
      G00759058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE OIL PUMP ASSY (See  LUBRICATION SYSTEM  ) 
  21. REMOVE OIL PUMP SEAL (See  LUBRICATION SYSTEM  ) 
  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. Rotate the stopper plate of the chain tensioner upward as shown in the illustration, push in the plunger of the tensioner.
    2. Rotate the stopper plate of the tensioner downward, insert a 2.5 mm (0.098 in.) diameter bar into the holes of the stopper plate and tensioner to hold the stopper plate.
      Fig 12: Removing Timing Chain Tensioner
      G00759059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE CHAIN TENSIONER SLIPPER 
    1. Remove the bolt and chain tensioner slipper
  24. REMOVE CHAIN VIBRATION DAMPER NO. 1 
    1. Remove the 2 bolts and 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, 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.

    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 sprockets.
      Fig 13: Locating Timing Mark On Timing Chain
      G00759060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL OIL PUMP SEAL (See ) 

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

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

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

      Fig 14: Installing Transverse Engine Mounting Bracket
      G00759061Courtesy 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 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.
      Fig 15: Installing Torque Of Engine Mounting Insulator RH
      G00759062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 

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

  32. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY 
    1. Apply a light coat of engine oil to 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  ) 

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

  35. INSTALL CRANKSHAFT DAMPER SUB-ASSY 
    1. Align 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 Torque Of Crankshaft Damper
      G00759063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL CYLINDER HEAD COVER SUB-ASSY 
    1. Apply the 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 the seal packing.
      • Do not start the engine within 2 hours of installation.
      Fig 17: Locating Cylinder Head Cover Seal Packing
      G00759064Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the cylinder head cover with the 9 bolts, 2 seal washers and 2 nuts.
    3. Using several steps, tighten the bolts and 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 
    1. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) 
      Fig 18: Installing Torque Of Cylinder Head Cover
      G00759065Courtesy 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: Installing Cylinder Head Cover No. 2
      G00759066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL GENERATOR ASSY (See  GENERATORS & REGULATORS  ) 
  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 VANE PUMP V BELT (See  DRIVE BELT  ) 
  43. ADJUST FAN AND GENERATOR V BELT (See  DRIVE BELT  ) 
  44. INSPECT DRIVE BELT DEFLECTION AND TENSION (See  ENGINE  ) 
  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. INSTALL ENGINE UNDER COVER RH 
    1. Torque: 
    2. 5.0 N.m (51 kgf.cm, 44 in.lbf) for Bolt 
    3. 5.0 N.m (51 kgf.cm, 44 in.lbf) for Nut 
  47. ADD ENGINE OIL 
  48. CHECK FOR ENGINE OIL LEAKS 
  49. ADD ENGINE COOLANT (See  ENGINE COOLANT  ) 
  50. CHECK FOR ENGINE COOLANT LEAKS (See  ENGINE COOLANT  ) 
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