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Timing Chain (2AZ-FE): Replacement

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE HOOD SUB-ASSY 
  2. REMOVE FRONT WHEEL RH 
  3. REMOVE ENGINE UNDER COVER NO.1 
  4. REMOVE FRONT FENDER SPLASH SHIELD FRONT RH 
  5. REMOVE FRONT FENDER APRON SEAL RH 
  6. DRAIN ENGINE OIL 
    1. Install a new gasket and the drain plug after draining engine oil.
      1. Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) 
  7. REMOVE EXHAUST PIPE ASSY FRONT 
  8. REMOVE ENGINE MOVING CONTROL ROD W/BRACKET (See  REPLACEMENT  ) 
  9. REMOVE ENGINE MOUNTING STAY NO.2 RH 
  10. REMOVE ENGINE MOUNTING BRACKET NO.2 RH 
  11. REMOVE FAN AND GENERATOR V BELT (See  FAN AND GENERATOR V BELT (2AZ-FE)  ) 
  12. REMOVE ENGINE COVER SUB-ASSY NO.1 
  13. DISCONNECT ENGINE WIRE 
  14. REMOVE GENERATOR ASSY 
  15. REMOVE VANE PUMP ASSY (See  OVERHAUL  ) 
    NOTE: Do not disconnect the hose.
  16. REMOVE IGNITION COIL ASSY 
  17. DISCONNECT VENTILATION HOSE No.1 
  18. DISCONNECT VENTILATION HOSE NO.2 
  19. REMOVE ENGINE COVER SUB-ASSY NO.1 
  20. REMOVE CYLINDER HEAD COVER SUB-ASSY (See  OVERHAUL  ) 
  21. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See  VALVE CLEARANCE (2AZ-FE)  ) 
  22. REMOVE CRANKSHAFT PULLEY 
    1. Using SST, fix the pulley and loosen the bolt.
      1. SST 09213-54015 (91651-60855), 09330-00021
      Fig 1: Loosening Crankshaft Pulley Bolt
      G03032994Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the bolt and pulley.
      1. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
    Fig 2: Removing Crankshaft Pulley
    G03032995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE CRANKSHAFT POSITION SENSOR 
  24. REMOVE OIL PAN SUB-ASSY (See  OVERHAUL  ) 
  25. REMOVE CHAIN TENSIONER ASSY NO.1 (See  OVERHAUL  
  26. REMOVE V-RIBBED BELT TENSIONER ASSY (See  REPLACEMENT  ) 
  27. INSTALL ENGINE HANGER NO.1 
    1. Install the engine hanger No. 1 and No. 2 with the bolts as shown in the illustration. Parts No.:
      ENGINE HANGER NUMBER

      Engine hanger No. 1 12281-28010
      Engine hanger No. 2 12282-28010
      Bolt 91512-61020
      1. Torque: 38 N.m (387 kgf.cm, 30 ft.lbf) 
    Fig 3: Installing Engine Hanger
    G03032996Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE ENGINE MOUNTING INSULATOR 
    1. Attach the engine chain hoist to the engine hangers.
      CAUTION: Do not attempt to hang the engine by hooking the chain to any other part.
    2. Remove the bolt and disconnect the engine mounting insulator FR.
      Fig 4: Removing Engine Mounting Insulator FR
      G03032997Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and disconnect the steering gear return hose clamp from the frame.
      Fig 5: Disconnecting Steering Gear Return Hose Clamp From Frame
      G03032998Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 4 nuts from the engine mounting insulator RH.
    5. Raise the engine and remove the engine mounting insulator RH.
    Fig 6: Removing Engine Mounting Insulator RH
    G03032999Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE ENGINE MOUNTING BRACKET RH 
    1. Remove the 3 bolts and engine mounting bracket.
    Fig 7: Removing Engine Mounting Bracket RH
    G03033000Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSSY 
    1. Remove the stud bolt for the drive belt tensioner from the cylinder block.
    2. Remove the 14 bolts and 2 nuts.
    3. Pry out the timing chain cover with a screwdriver.
    NOTE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder block and cylinder head.
    Fig 8: Removing Timing Chain Cover
    G03033001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1 
  32. REMOVE CHAIN TENSIONER SLIPPER 
  33. REMOVE CHAIN VIBRATION DAMPER NO.1 
  34. REMOVE CHAIN SUB-ASSY 
  35. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET 
  36. REMOVE NO.2 CHAIN SUB-ASSY 
    1. Turn the crankshaft counterclockwise 90°, and align an adjusting hole of the oil pump driven sprocket with the groove of the oil pump.
      Fig 9: Adjusting Hole Of Oil Pump Driven Sprocket With Groove Of Oil Pump
      G03033002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Put a bar(phi 4.0 mm (0.16 in.)) in the adjusting hole of the oil pump driven sprocket to temporarily lock the sprocket in position. Remove the nut.
      Fig 10: Putting Bar In Adjusting Hole Of Oil Pump Driven Sprocket For Temporarily Locking Sprocket In Position
      G03033003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove The bolt, chain tensioner plate and spring.
    4. Remove the chain tensioner, oil pump driven sprocket and chain.
    Fig 11: Removing Chain Tensioner, Oil Pump Driven Sprocket And Chain
    G03033004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL NO.2 CHAIN SUB-ASSY 
    1. Set the crankshaft key into the left horizontal position.
    2. Turn the cutout of the drive shaft to the top.
      Fig 12: Setting Crankshaft Key Into Left Horizontal Position
      G03033005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Align the mark links (yellow colored links) with the timing marks of the sprocket as shown in the illustration.
    4. Insert the sprockets with chain to the crankshaft and oil pump shaft.
    5. Temporarily tighten the oil pump driven sprocket with the nut.
      Fig 13: Aligning Timing Chain Mark Links (Yellow Colored Links) With Timing Marks Of Sprocket
      G03033006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Insert the damper spring into the adjusting hole, and install the chain tensioner plate with the nut.
      1. Torque: 12 N.m (122 kgf.cm, 9.0 ft.lbf) 
      Fig 14: Installing Chain Tensioner Plate
      G03033007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Align the adjusting hole of the oil pump driven sprocket with the groove of the oil pump.
    8. Put a bar (phi 4 mm (0.16 in.) in the adjusting hole of the oil pump driven sprocket to temporarily lock the sprocket in position. Install the nut.
      1. Torque: 30 N.m (306 kgf.cm, 22 ft.lbf) 
      Fig 15: Putting Bar In Adjusting Hole Of Oil Pump Driven Sprocket For Temporarily Locking Sprocket In Position
      G03033008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Rotate the crankshaft counterclockwise 90°, and align the crankshaft key to the top.
    Fig 16: Rotating Crankshaft Counterclockwise 90°, And Aligning Crankshaft Key To Top
    G03033009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL CHAIN VIBRATION DAMPER NO.1 
    1. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) 
  39. INSTALL CHAIN SUB-ASSY 
    1. Set the No.1 cylinder to TDC/compression.
      1. Align the timing marks of the camshaft timing sprockets and bearing caps (No. 1 and No. 2).
        Fig 17: Aligning Timing Marks Of Camshaft Timing Sprockets And Bearing Caps
        G03033010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward.
      Fig 18: Setting Key On Crankshaft Upward
      G03033011Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Align the mark link (gold or orange colored link) with the timing mark of the crankshaft timing sprocket.
      Fig 19: Aligning Timing Chain Mark Link (Gold Or Orange Colored Link) With Timing Mark Of Crankshaft Timing Sprocket
      G03033012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, tap in the sprocket.
      1. SST 09309-37010
      Fig 20: Installing Sprocket Using SST
      G03033013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Align the mark links (gold or yellow colored links) with the timing marks of the camshaft timing gear and camshaft timing sprocket. Install the chain.
    Fig 21: Aligning Timing Chain Mark Link (Gold Or Yellow Colored Link) With Timing Mark Of Camshaft Timing Gear And Timing Sprocket
    G03033014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL CHAIN TENSIONER SLIPPER 
    1. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf) 
  41. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 (See  OVERHAUL  ) 
  42. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSSY 
    NOTE:
    • Remove any oil from the contact surface.
    • Install the chain cover within 3 minutes after applying seal packing.
    • Do not start the engine for at least 2 hours after installing.
    1. Remove any old packing (FIPG) 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 seal packing in a continuous bead (seal width: 2.0 mm (0.079 in.)) as shown in the illustration.

      Seal packing: Part No. 08826-00080 or equivalent 

      Fig 22: [Applying Seal Packing To Contact Surface Of Timing Chain Cover]
      G03033015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply seal packing in a continuous bead (seal width: 3.0 to 4.0 mm (0.12 to 0.16 in.)) as shown in the illustration.

      Seal packing: Part No. 08826-00080 or equivalent 

      Fig 23: Applying Seal Packing To Timing Chain Cover
      G03033016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the timing chain cover with the 14 bolts and 2 nuts.
      1. Torque: 
      2. 9.0 Nm (92 kgf.cm, 80 in..lbf) for bolt A 
      3. 21 Nm (214 kgf.cm, 15 ft.lbf) for bolt B 
      4. 43 Nm (438 kgf.cm, 32 ft.lbf) for bolt C 
      5. 9.0 Nm (92 kgf.cm, 80 in..lbf) for nut 
    5. Install the stud bolt to the drive belt tensioner.
      1. Torque: 10 N.m (102 kgf.cm, 7 ft.lbf) 
    Fig 24: Installing Timing Chain Cover
    G03033017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL CHAIN TENSIONER ASSY NO.1 
  44. INSTALL V-RIBBED BELT TENSIONER ASSY (See  REPLACEMENT  ) 
  45. INSTALL ENGINE MOUNTING BRACKET RH 
    1. Install the engine mounting bracket with the 3 bolts.
      1. Torque: 54 N.m (551 kgf.cm, 40 ft.lbf) 
    Fig 25: Installing Engine Mounting Bracket RH
    G03033018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSTALL TRANSVERSE ENGINE MOUNTING INSULATOR
    1. Raise the engine and install the engine mounting insulator RH.
    2. Install the engine mounting insulator RH with the 4 nuts.
      1. Torque: 
      2. 95 N.m (969 kgf.cm, 70 ft.lbf) for bolt A 
      3. 87 N.m (887 kgf.cm, 64 ft.lbf) for bolt B 
      Fig 26: Installing Transverse Engine Mounting Insulator
      G03033019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the steering gear return hose clamp to the frame with the bolt.
      1. Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf) 
      Fig 27: Installing Steering Gear Return Hose Clamp To Frame
      G03033020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the engine mounting insulator FR with the bolt.
      1. Torque: 87 N.m (887 kgf.cm, 64 in..lbf) 
    Fig 28: Installing Engine Mounting Insulator FR
    G03033021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL OIL PAN SUB-ASSY (See  OVERHAUL  ) 
  48. INSTALL CRANKSHAFT POSITION SENSOR (See  OVERHAUL  ) 
  49. INSTALL CRANKSHAFT PULLEY 
    1. Install the crankshaft pulley.
      1. Align the pulley set key with the key groove of the pulley, and side on the pulley.
      2. Using SST, install the pulley bolt.
        1. SST 09213-54015 (91651-60855), 09330-00021
        2. Torque: 180 N.m (1,835 kgf.cm, 133 ft.lbf) 

    HINT:

    Apply a light coat of engine oil to the bolt threads and the area beneath the bolt heads that come in contact with the washers.

    Fig 29: Installing Crankshaft Pulley
    G03033022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSTALL CHAIN TENSIONER ASSY NO.1 
    1. Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out.
      Fig 30: Pushing In Plunger And Applying Hook To Pin
      G03033023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new gasket and the chain tensioner with the 2 nuts.
      1. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) 
      NOTE: If the hook is released while inserting, apply the hook again, and insert the chain tensioner.
      Fig 31: Installing Chain Tensioner With Gasket
      G03033024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Turn the crankshaft counterclockwise and check that the plunger knock pin is disconnected from the hook.
      Fig 32: Turning Crankshaft Counterclockwise And Disconnecting Plunger Knock Pin From Hook
      G03033025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Turn the crankshaft clockwise and check that the slipper is pushed by the plunger.
    Fig 33: Turning Crankshaft Clockwise And Check That Slipper Pushed By Plunger
    G03033026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. INSTALL CYLINDER HEAD COVER SUB-ASSY (See  CAMSHAFT (2AZ-FE)  ) 
  52. INSTALL IGNITION COIL ASSY 
    1. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf) 
  53. INSTALL VANE PUMP ASSY (See  OVERHAUL  ) 
  54. INSTALL GENERATOR ASSY (See  GENERATOR  ) 
  55. INSTALL ENGINE WIRE 
  56. INSTALL FAN AND GENERATOR V BELT (See  FAN AND GENERATOR V BELT (2AZ-FE)  ) 
  57. INSTALL ENGINE MOUNTING BRACKET NO.2 RH 
    1. Torque: 52 N.m (531 kgf.cm, 38 ft.lbf) 
  58. INSTALL ENGINE MOUNTING STAY NO.2 RH 
    1. Torque: 64 N.m (653 kgf.cm, 47 ft.lbf) 
  59. INSTALL ENGINE MOVING CONTROL ROD W/BRACKET (See  REPLACEMENT  ) 
  60. INSTALL EXHAUST PIPE ASSY FRONT (See  REPLACEMENT  ) 
  61. INSTALL FRONT WHEEL RH 
  62. INSTALL HOOD SUB-ASSY 
    1. Torque: 13 N.m (133 kgf.cm, 10 ft.lbf) 
  63. ADD ENGINE OIL 
  64. CHECK FOR ENGINE OIL LEAKS 
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