LEMON Manuals: Even more car manuals for everyone
Home >> Scion >> 2007 >> tC Spec, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (2AZ-FE) >> Timing Chain >> Installation

Timing Chain: Installation

  1. INSTALL NO. 2 CHAIN SUB-ASSEMBLY 
    1. Set the crankshaft key in the left horizontal position.
    2. Turn the cutout of the drive shaft to the top.
      Fig 1: Locating Chain Sub-Assembly
      G04865391Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Align the yellow mark links with the timing marks of the each gear as shown in the illustration.
    4. Install the gears onto the crankshaft and oil pump shaft with the chain wrapped on the gears.
    5. Temporarily tighten the oil pump drive shaft gear with the nut.
      Fig 2: Identifying Oil Pump Drive Shaft Gear, Timing Gear And Mark Line
      G04865392Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Insert the damper spring into the adjusting hole, then install the chain tensioner plate with the bolt.

      Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

      Fig 3: Locating Chain Tensioner Plate With Bolt
      G04865393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pump.
    8. Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, then tighten the nut.

      Torque: 29.5 N*m (301 kgf*cm, 22 ft.*lbf) 

      Fig 4: Adjusting Hole Of Oil Pump Drive Shaft Gear To Lock Gear
      G04865380Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Turn the crankshaft clockwise by 90° to position the crankshaft key upward.
      10. Fig 5: Turning Crankshaft Position
      G04865395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL CRANKSHAFT TIMING SPROCKET 
  3. INSTALL NO. 1 CHAIN VIBRATION DAMPER 
    1. Install the chain vibration damper with the 2 bolts.

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

  4. INSTALL CHAIN SUB-ASSEMBLY 
    1. Set the No. 1 cylinder to TDC/compression.
      1. Turn the camshafts with a wrench in the hexagonal lobe to align the timing marks of the camshaft timing gear with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration.
        Fig 6: Identifying Timing Marks Of Camshaft Timing Gear
        G04865396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Using the crankshaft pulley bolt, turn the crankshaft to position the key on the crankshaft upward.
        Fig 7: Identifying Crankshaft Upward Position
        G04865397Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the chain onto the crankshaft timing sprocket with the gold or orange mark link aligned with the timing mark on the crankshaft timing gear.
      Fig 8: Identifying Crankshaft Timing Mark And Mark Link
      G04865398Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a hammer, tap in the crankshaft timing sprocket.

      SST 09309-37010 

      Fig 9: Identifying SST
      G04865399Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Align the gold or yellow links with each timing mark located on the camshaft timing gear and sprocket, then install the chain.
      5. Fig 10: Identifying Timing Mark On Camshaft Timing Gear And Sprocket
      G04865400Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL CHAIN TENSIONER SLIPPER 
    1. Install the chain tensioner slipper with the bolt.

      Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 

  6. INSTALL TIMING CHAIN GUIDE 
    1. Install the timing chain guide with the bolt.

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

      Fig 11: Locating Timing Chain Guide With Bolt
      G04865378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE 
    1. Install the sensor plate with the "F" mark facing forward.
      2. Fig 12: Installing Crankshaft Position Sensor Plate
      G04865402Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY 
    1. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.
    2. Apply of seal packing (Diameter 2.0 mm (0.079 in.)) as shown in the illustration.

      Seal packing: 

      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent 

      NOTE:
      • Remove any oil from the contact surface.
      • Install the chain cover within 3 minutes of applying seal packing.
      • Do not add engine oil for at least 2 hours after installing the chain cover.
      Fig 13: Identifying Seal Packing
      G04865403Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply a continuous bead of seal packing as shown in the illustration.

      Seal packing: 

      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent 

      NOTE:
      • Remove any oil from the contact surface.
      • Install the chain cover within 3 minutes of applying seal packing.
      • Do not add engine oil for at least 2 hours after installing the chain cover.
      Fig 14: Locating Area Of Seal
      G04865404Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the timing chain cover with the 14 bolts and 2 nuts.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) for bolt A 25 N*m (255 kgf*cm, 18 ft.*lbf) for bolt B 55 N*m (561 kgf*cm, 41 ft.*lbf) for bolt C 11 N*m (112 kgf*cm, 8 ft.*lbf) for nut 

      HINT:

      Bolt length:

      TIMING CHAIN COVER BOLT LENGTH CHART

      Bolt A 30 mm (1.18 in.) length for 10 mm head
      Bolt B 30 mm (1.18 in.) length for 12 mm head
      Bolt C 40 mm (1.57 in.) length for 14 mm head
      Bolt D 65 mm (2.56 in.) length for 14 mm head
      Fig 15: Locating Timing Chain Cover With Bolts
      G04865405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using an E10 "torx" socket, install the stud bolt for the V-ribbed belt tensioner.

      Torque: 21.5 N*m (219 kgf*cm, 16 ft.*lbf) 

      Fig 16: Installing Stud Bolt For V-Ribbed Belt Tensioner
      G04865376Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Release the ratchet pawl, then fully push in the plunger and hook the hook to the pin so that the plunger is in the position shown in the illustration.
      Fig 17: Pushing Plunger And Hook
      G04865346Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new gasket and the chain tensioner with the 2 nuts.

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

      NOTE: When installing the chain tensioner, set the hook again if the hook releases the plunger.
      Fig 18: Identifying Chain Tensioner, Gasket And Nuts
      G04865408Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL CRANKSHAFT PULLEY 
    1. Using SST, fix the pulley in place and tighten the bolt.

      SST 09213-54015 (91651 -60855), 09330-00021 

      Torque: 180 N*m (1,835 kgf*cm, 133 ft.*lbf) 

      Fig 19: Installing Crankshaft Pulley
      G04865372Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Turn the crankshaft counterclockwise, then disconnect the plunger knock pin from the hook.
      Fig 20: Disconnecting Plunger Knock Pin From Hook
      G04865348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Turn the crankshaft clockwise, then check that the plunger is extended.
      Fig 21: Identifying Plunger Extended
      G04865411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the wire harness protector clamp.
    5. Install the bolt.

      Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf) 

      6. Fig 22: Connecting Wire Harness Protector Clamp
      G04865412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL OIL PAN SUB-ASSEMBLY 
    1. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.
    2. Apply a continuous bead of seal packing (Diameter 3.0 to 4.0 mm (0.118 to 0.157 in.)) as shown in the illustration.

      Seal packing: 

      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent 

      NOTE:
      • Remove any oil from the contact surface.
      • Install the oil pan within 3 minutes of applying seal packing.
      • Do not add engine oil for at least 2 hours after installing the oil pan.
      3. Fig 23: Identifying Seal Diameter
      G04865413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the oil pan to the cylinder block.
    4. Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration.

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

      Fig 24: Locating Oil Pan Bolts Sequence
      G04865414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Place a transmission jack underneath the engine, then put a wooden block on the jack.
      6. Fig 25: Placing Transmission Jack Underneath Engine
      G04865361Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the chain block and sling device.
    7. Remove the No. 1 and No. 2 engine hangers.
  12. INSTALL CRANKSHAFT POSITION SENSOR (See  REMOVAL  ) 
  13. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Install the V-ribbed belt tensioner with the bolt and nut.

      Torque: 59.5 N*m (607 kgf*cm, 44 ft.*lbf) 

      NOTE: Do not lift the engine more than necessary.
      2. Fig 26: Locating V-Ribbed Belt Tensioner And Bolt
      G04865367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Remove any old packing material from the contact surface.
    2. Apply seal packing to the 2 locations shown in the illustration.

      Seal packing: 

      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent 

      NOTE:
      • Remove any oil from the contact surface.
      • Install the oil pan within 3 minutes of applying seal packing.
      • Do not add engine oil for at least 2 hours after installing the oil pan.
      Fig 27: Locating Area Of Seal Packing
      G04865417Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the cylinder head cover with the 8 bolts and 2 nuts.

      Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) for bolt A 14 N*m (143 kgf*cm, 10 ft.*lbf) for bolt B 11 N*m (112 kgf*cm, 8 ft.*lbf) for nut 

      Fig 28: Locating Cylinder Head Cover Bolts And Nuts
      G04865418Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the engine wire with the bolt (labeled A).

      Torque: 8.4 N*m (86 kgf*cm, 74 in*lbf) 

    5. Connect the clamp of the engine wire (labeled B).
      Fig 29: Locating Clamp Of Engine Wire Label
      G04865365Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the 2 ventilation hoses to the cylinder head cover.
  15. INSTALL IGNITION COIL ASSEMBLY (See  REMOVAL  ) 
    Fig 30: Locating Ventilation Hoses To Cylinder Head Cover
    G04865364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL ENGINE MOUNTING INSULATOR RH 
    1. Install the engine mounting insulator RH with the 4 bolts and 2 nuts.

      Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) 

      Fig 31: Locating Engine Mounting Insulator With Bolts And Nuts
      G04865363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the front engine mounting insulator with the bolt and nut.

      Torque: 52 N*m (530 kgf*cm, 38 ft*lbf) 

      Fig 32: Locating Front Engine Mounting Insulator With Bolt And Nut
      G04865362Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the 2 clamps of the engine wire.
    4. Install the wire harness protector with the bolt.
      Fig 33: Locating Clamps Of Engine Wire
      G04865360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the No. 1 oil reservoir bracket with the 2 bolts.

      Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

      Fig 34: Locating Oil Reservoir Bracket With Bolts
      G04865359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the return tube with the 2 bolts.

      Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

      Fig 35: Locating Oil Reservoir Bolt
      G04865358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the vane pump oil reservoir onto the No. 1 oil reservoir bracket.
      Fig 36: Identifying Vane Pump Oil Reservoir
      G04865357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install the radiator reservoir with the bolt.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

      9. Fig 37: Locating Radiator Reservoir With Bolt
      G04865427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL VANE PUMP ASSEMBLY 
  18. INSTALL GENERATOR ASSEMBLY (See  INSTALLATION  ) 
  19. INSTALL FAN AND GENERATOR V BELT (See  REMOVAL  )
  20. INSTALL FRONT EXHAUST PIPE ASSEMBLY (See  DISASSEMBLY  ) 
  21. ADD ENGINE OIL (See  REPLACEMENT  ) 
  22. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  23. CHECK FOR ENGINE OIL LEAKS 
  24. CHECK FOR EXHAUST GAS LEAKS 
  25. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. Install the engine cover with the 2 nuts.

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

      2. Fig 38: Locating Engine Cover And Nuts
      G04869370Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL FRONT FENDER APRON SEAL RH 
  27. INSTALL ENGINE UNDER COVER LH 
  28. INSTALL ENGINE UNDER COVER RH 
  29. INSTALL FRONT WHEEL RH 
  30. INSTALL HOOD SUB-ASSEMBLY 
  31. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION ).
      NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
scientia non olet · About LEMON Manuals