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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 Cylinder Head Cover No. 2
      G03197427Courtesy 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 Coils
      G03197428Courtesy 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
      G03197429Courtesy 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
      G03197430Courtesy 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 Cylinder Head Cover
      G03197431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE FAN AND GENERATOR V BELT (See  REPLACEMENT   ) 
  8. REMOVE GENERATOR ASSY (See  REPLACEMENT  ) 
  9. REMOVE ENGINE UNDER COVER RH 
  10. DRAIN ENGINE OIL 
  11. DRAIN ENGINE COOLANT (See  REPLACEMENT  ) 
  12. REMOVE VANE PUMP V BELT (See  REPLACEMENT   ) 
  13. REMOVE WATER PUMP PULLEY (See  REPLACEMENT  ) 
  14. REMOVE WATER PUMP ASSY (See  REPLACEMENT  ) 
  15. REMOVE CRANKSHAFT DAMPER SUB-ASSY 
    1. Set the No. 1 cylinder to the TDC/compression.
      1. Turn the crankshaft damper until its timing notch and the timing mark "0" of the chain cover are aligned.
      2. Check that both timing marks on the camshaft timing sprocket and the 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: Identifying Timing Marks On Camshaft Timing Sprocket & Camshaft Timing Gear
        G03197432Courtesy 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 Crankshaft Damper Pulley Bolt
      G03197433Courtesy 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 the O-ring.
  17. REMOVE CRANKSHAFT POSITION SENSOR (See  REPLACEMENT  ) 
    Fig 8: Removing Camshaft Timing Oil Control Valve
    G03197434Courtesy 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: Placing Wooden Block On Jack Underneath Engine
      G03197435Courtesy 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, and nut, and then remove the engine mounting insulator RH.
      Fig 10: Removing Engine Mounting Insulator RH
      G03197436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE ENGINE MOUNTING BRACKET RH 
    1. Remove the 4 bolts and the engine mounting bracket RH.
  20. REMOVE OIL PUMP ASSY (See  REPLACEMENT  ) 
  21. REMOVE OIL PUMP SEAL (See  REPLACEMENT  ) 
    Fig 11: Removing Engine Mounting Bracket RH
    G03197437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 downward, 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: Pushing In Plunger Of Tensioner While Rotating Stopper Plate Of Chain Tensioner Upward
      G03197438Courtesy 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 & Crankshaft Timing Sprocket With Mark Plate Of Timing Chain
      G03197439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL OIL PUMP SEAL (See  REPLACEMENT  ) 

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

  28. INSTALL OIL PUMP ASSY (See  REPLACEMENT  ) 
  29. INSTALL WATER PUMP ASSY (See  REPLACEMENT  ) 
  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 Engine Mounting Bracket RH
      G03197440Courtesy 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: 

      1. Bolt A 45 N.m (459 kgf.cm, 33 ft.lbf) 
      2. Bolt B 52 N.m (530 kgf.cm, 38 ft.lbf) 
      3. Nut 52 N.m (530 kgf.cm, 38 ft.lbf) 
    2. Install the liquid tube with the bolt.

      Torque: 

      1. Bolt C 9.8 N.m (100 kgf.cm, 7.2 ft.lbf) 
        Fig 15: Installing RH Engine Mounting Insulator
        G03197441Courtesy 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 onto 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  REPLACEMENT  ) 
  34. INSTALL WATER PUMP PULLEY (See  REPLACEMENT  ) 

    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 Crankshaft Damper Pulley Bolt
      G03197442Courtesy 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 of applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
        Fig 17: Applying Seal Packing
        G03197443Courtesy 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, uniformly tighten the bolts and the nuts 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: Installing Cylinder Head Cover
    G03197477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL CYLINDER HEAD COVER NO.2 
    1. First tighten A nuts, then tighten bolts B.

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

      Fig 19: Installing Cylinder Head Cover No 2
      G03197445Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL GENERATOR ASSY (See  REPLACEMENT  ) 
  40. INSTALL VANE PUMP V BELT 
    1. Temporarily install the V-ribbed belt onto each pulley.
  41. INSTALL FAN AND GENERATOR V BELT 
    1. Temporarily install the V-ribbed belt onto each pulley.
  42. ADJUST FAN AND GENERATOR V BELT (See  REPLACEMENT   ) 
  43. ADJUST VANE PUMP V BELT (See  REPLACEMENT   ) 
  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  REPLACEMENT  ) 
  49. CHECK FOR ENGINE COOLANT LEAKS (See  ON-VEHICLE INSPECTION  ) 
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