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Timing Chain Sub-ASSY (2ZZ-GE): Replacement

  1. DISCONNECT BATTERY NEGATIVE TERMINAL 
  2. DRAIN COOLANT (See  ENGINE COOLANT (2ZZ-GE)  ) 
  3. REMOVE FRONT WHEEL RH 
  4. REMOVE ENGINE UNDER COVER RH 
  5. REMOVE FRONT SUSPENSION BAR ASSY TOWER (See  OVERHAUL  ) 
  6. REMOVE CYLINDER HEAD COVER NO. 2 
    1. Remove the 3 bolts and nut, then remove the cylinder head cover No. 2.
  7. REMOVE WIRE HARNESS PROTECTOR (See  FAN AND GENERATOR V BELT (2ZZ-GE)  ) 
  8. SEPARATE SUCTION HOSE SUB-ASSY (See  FAN AND GENERATOR V BELT (2ZZ-GE)  ) 
  9. REMOVE AIR SWITCHING VALVE ASSY (See  PRESSURE SENSOR (TURBO PRESSURE SENSOR) (2ZZ-GE)  ) 
  10. REMOVE FAN AND GENERATOR V BELT (See  FAN AND GENERATOR V BELT (2ZZ-GE)  ) 
  11. REMOVE GENERATOR BRACKET NO. 1 (See  REPLACEMENT  ) 
  12. REMOVE GENERATOR ASSY (See  REPLACEMENT  ) 
  13. REMOVE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING) (See  REPLACEMENT  ) 

    HINT:

    Hang up the hoses instead of detaching.

  14. REMOVE SHIFT LEVER KNOB SUB-ASSY 
  15. REMOVE CONSOLE PANEL UPPER (See  REPLACEMENT  ) 
  16. REMOVE PARKING BRAKE HOLE COVER SUB-ASSY (See  REPLACEMENT  ) 
  17. REMOVE CONSOLE BOX CARPET 
  18. REMOVE CONSOLE BOX SUB-ASSY REAR (See  REPLACEMENT  ) 
  19. REMOVE EXHAUST PIPE ASSY FRONT (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  20. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSY RH (See  REPLACEMENT  ) 
  21. REMOVE V-RIBBED BELT TENSIONER ASSY 

    HINT:

    Jack the engine up and down to remove the bolt.

  22. REMOVE IGNITION COIL ASSY (See  REPLACEMENT  ) 
  23. REMOVE CYLINDER HEAD COVER SUB-ASSY (See  REPLACEMENT  ) 
  24. REMOVE MANIFOLD STAY 
    1. Remove the 2 bolts and nut, then remove the manifold stay.
    Fig 1: Removing Bolts, Nut And Manifold Stay
    G02613445Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1 
  26. REMOVE EXHAUST MANIFOLD 
    1. Remove the 4 bolts and 2 nuts, then remove the exhaust manifold and gasket.
    Fig 2: Removing Bolts, Nuts And Exhaust Manifold And Gasket
    G02613446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE WATER PUMP PULLEY (See  WATER PUMP ASSY (2ZZ-GE)  ) 

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

  28. REMOVE WATER PUMP ASSY (See  WATER PUMP ASSY (2ZZ-GE)  ) 
  29. REMOVE TRANSVERSE ENGINE MOUNTING BRACKET 
    1. Remove the 4 bolts and engine mounting bracket.
    Fig 3: Removing Bolts And Engine Mounting Bracket
    G02613447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE CRANKSHAFT POSITION SENSOR 
  31. SET NO. 1 CYLINDER TO TDC/COMPRESSION 
    1. Turn the crankshaft pulley until its groove and the timing mark "0" of the timing chain cover are aligned.
    2. Check that the point marks of the camshaft timing sprocket and the VVT timing sprocket are as shown in the illustration.

    HINT:

    If not, turn the crankshaft 1 revolution to align the marks as above.

    Fig 4: Checking Point Marks Of Camshaft Timing Sprocket And VVT Timing Sprocket
    G02613448Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE CRANKSHAFT PULLEY 
    1. Using SST, remove the pulley bolt.

      SST 09213-70011 (09213-70020), 09330-00021

      Fig 5: Removing Pulley Bolt
      G02613449Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the crankshaft pulley.

    SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021, 09957-04010)

    Fig 6: Removing Crankshaft Pulley
    G02613450Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE CHAIN TENSIONER ASSY NO. 1 
    1. Remove the 2 nuts and chain tensioner assy No. 1.
    NOTE: Do not turn the crankshaft without the chain tensioner.
    Fig 7: Removing Nuts And Chain Tensioner Assy No. 1
    G02613451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSY 
    1. Remove the 13 bolts and timing chain cover.
    2. Remove the 2 gaskets from the timing chain cover.
    NOTE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder head and cylinder block.
    Fig 8: Removing Bolts And Timing Chain Cover
    G02613452Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE TIMING CHAIN OR BELT COVER OIL SEAL (See  TIMING CHAIN OR BELT COVER OIL SEAL (2ZZ-GE)  ) 
  36. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO. 1 
  37. REMOVE CHAIN TENSIONER SLIPPER 
    1. Remove the bolt and chain tensioner slipper.
  38. REMOVE CHAIN VIBRATION DAMPER NO. 1 
    1. Remove the 2 bolts and chain vibration damper No. 1.
  39. REMOVE CHAIN SUB-ASSY 
    1. Using 2 screwdrivers, pry out the timing chain together with the crankshaft timing gear, as shown in the illustration.
    NOTE:
    • Use a shop rag to protect the engine.
    • If revolving the camshafts with the chain off the sprockets, turn the crankshaft 1/4 revolution to prevent the valves from coming into contact with the pistons.
    Fig 9: Prying Out Timing Chain Together With Crankshaft Timing Gear
    G02613453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL CHAIN VIBRATION DAMPER NO. 1 
    1. Install the chain vibration damper No. 1 with the 2 bolts.

    Torque: 21 N.m (214 kgf.cm, 15 ft.lbf) 

  41. INSTALL CHAIN SUB-ASSY 
    1. Set the No. 1 cylinder to the TDC/compression.
      1. Turn the hexagonal wrench head portion of the camshafts so as to align the point marks of the camshaft timing sprockets.
        Fig 10: Aligning Point Marks Of Camshaft Timing Sprockets
        G02613454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Turn the crankshaft to set the set key on the crankshaft upward.
        Fig 11: Turning Crankshaft To Set Key On Crankshaft Upward
        G02613455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the timing chain on the crankshaft timing sprocket with the yellow mark link aligned with the timing mark on the crankshaft timing sprocket.

      HINT:

      A yellow color link and 2 orange color links are on the chain.

      Fig 12: Installing Timing Chain On Crankshaft Timing Sprocket With Yellow Mark Link
      G02613456Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, install the sprocket.

      SST 09223-22010

      Fig 13: Installing Sprocket
      G02613457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the timing chain onto the camshaft timing sprockets with the orange mark links aligned with the timing marks on the camshaft timing sprockets.
    Fig 14: Aligning With Timing Marks On Camshaft Timing Sprockets
    G02613458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL CHAIN TENSIONER SLIPPER 
    1. Install the chain tensioner slipper with the bolt.

      Torque: 21 N.m (214 kgf.cm, 15 ft.lbf) 

    2. Check that the chain tensioner slipper is caught on the cylinder head stopper.
    NOTE: Do not turn the crankshaft.
    Fig 15: Installing Chain Tensioner Slipper With Bolt
    G02613459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO. 1 
    1. Install the plate with the F mark facing forward.
    Fig 16: Installing Plate With F Mark Facing Forward
    G02613460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL TIMING CHAIN OR BELT COVER OIL SEAL (See  TIMING CHAIN OR BELT COVER OIL SEAL (2ZZ-GE)  ) 

    SST 09223-22010

  45. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSY 
    1. Remove any old packing (FIPG) material. Be careful not to drop any oil on the contact surface of the timing chain cover, cylinder head and cylinder block.
      • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
      • Thoroughly clean all components to remove all the loose material.
      • Using a non-residue solvent, clean both sealing surfaces.
    2. Apply a continuous bead of seal packing (Diameter 3 mm (0.118 in.)) as shown in the illustration.

      Seal packing: THREE BOND 1280 B or equivalent 

      NOTE:
      • Remove any oil from the contact surface.
      • Do not put in engine oil for at least 2 hours after installation.
      • Install a nozzle that has been cut to a 1.5 mm opening.
    3. Install the 2 gaskets onto the timing chain cover as shown in the illustration.
      Fig 17: Installing Gaskets Onto Timing Chain Cover
      G02613461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Apply a continuous bead of seal packing (Diameter 3 mm (0.118 in.) as shown in the illustration.

      Seal packing: THREE BOND 1280 B or equivalent 

      NOTE:
      • Remove any oil from the contact surface.
      • Do not put into engine oil within 2 hours of installation.
      • Install the chain cover, engine mounting bracket and water pump within 15 minutes of applying seal packing.
    5. Install the timing chain cover with the 13 bolts.
    6. Install the stud bolt.

      Torque: 

      21 N.m (214 kgf.cm, 15 ft.lbf) for (M8) bolt 

      11 N.m (112 kgf.cm, 8 ft.lbf) for (M6) bolt 

    7. Install the stud bolt.

    Torque: 9.5 N.m (97 kgf.cm, 84 in..lbf) 

    Fig 18: Installing Stud Bolt
    G02613462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSTALL CHAIN TENSIONER ASSY NO. 1 
    1. Check that the O-ring is clean, then set the hook as shown in the illustration.
      Fig 19: Checking O-Ring Is Clean
      G02613463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply engine oil to the chain tensioner, then install it.

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

    NOTE: When installing the tensioner, set the hook again if the hook releases the plunger.
    Fig 20: Applying Engine Oil To Chain Tensioner
    G02613464Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL CRANKSHAFT PULLEY 
    1. Align the pulley set key with the key groove of the pulley, then slide on the pulley.
    2. Using SST, install the pulley bolt.

      SST 09213-70011 (09213-70020), 09330-00021

      Torque: 120 N.m (1,224 kgf.cm, 89 ft.lbf) 

      Fig 21: Installing Pulley Bolt
      G02613465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Turn the crankshaft counterclockwise to disconnect the plunger knock pin from the hook.
      Fig 22: Disconnecting Plunger Knock Pin From Hook
      G02613466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Turn the crankshaft clockwise, then check that the slipper is pushed by the plunger.

    HINT:

    If the plunger is not extended, push the slipper into the chain tensioner with a screwdriver so that the hook is released from the knock pin and the plunger can be extended.

    Fig 23: Turning Crankshaft Clockwise
    G02613467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSTALL CRANKSHAFT POSITION SENSOR 

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

  49. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET 
    1. Install the engine mounting bracket with the 4 bolts.

    Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 

    Fig 24: Installing Engine Mounting Bracket With Bolts
    G02613468Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSTALL WATER PUMP ASSY (See  WATER PUMP ASSY (2ZZ-GE)  ) 
  51. INSTALL WATER PUMP PULLEY (See  WATER PUMP ASSY (2ZZ-GE)  ) 

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

  52. INSTALL EXHAUST MANIFOLD 
    1. Install a new gasket and the exhaust manifold with the 4 bolts and 2 nuts.

    Torque: 

    50 N.m (510 kgf.cm, 37 ft.lbf) for bolt A and nut A 

    20 N.m (204 kgf.cm, 14 ft.lbf) for bolt B 

    Fig 25: Installing New Gasket And Exhaust Manifold With Bolts And Nuts
    G02613469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1 

    Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) 

  54. INSTALL MANIFOLD STAY 
    1. Install the manifold stay with the 2 bolts and nut.

    Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 

    Fig 26: Installing Manifold Stay With Bolts And Nut
    G02613470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. INSTALL CYLINDER HEAD COVER SUB-ASSY (See  REPLACEMENT  ) 
  56. INSTALL IGNITION COIL ASSY 

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

  57. INSTALL V-RIBBED BELT TENSIONER ASSY 

    Torque: 

    29 N.m (296 kgf.cm, 21 ft.lbf) for nut 

    100 N.m (1,020 kgf.cm, 74 ft.lbf) for bolt 

  58. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSY RH 
    1. Install the engine mounting insulator RH with the 5 bolts and 2 nuts.

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

    Fig 27: Installing Engine Mounting Insulator RH With Bolts And Nuts
    G02613471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. INSTALL EXHAUST PIPE ASSY FRONT (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  60. INSTALL CONSOLE BOX SUB-ASSY REAR 
  61. INSTALL CONSOLE BOX CARPET 
  62. INSTALL PARKING BRAKE HOLE COVER SUB-ASSY 
  63. INSTALL CONSOLE PANEL UPPER 
  64. INSTALL SHIFT LEVER KNOB SUB-ASSY 
  65. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING) (See  REPLACEMENT  ) 
  66. INSTALL GENERATOR ASSY (See  REPLACEMENT  ) 
  67. INSTALL GENERATOR BRACKET NO. 1 (See  REPLACEMENT  ) 
  68. INSTALL SUCTION HOSE SUB-ASSY 

    Torque: 9.8 N.m (100 kgf.cm, 87 in..lbf) 

  69. INSTALL AIR SWITCHING VALVE ASSY (See  PRESSURE SENSOR (TURBO PRESSURE SENSOR) (2ZZ-GE)  ) 
  70. INSTALL FRONT SUSPENSION BAR ASSY TOWER (See  OVERHAUL  ) 
  71. INSTALL FRONT WHEEL RH 

    Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf) 

  72. CONNECT BATTERY NEGATIVE TERMINAL 
  73. ADD COOLANT (See  ENGINE COOLANT (2ZZ-GE)  ) 
  74. CHECK FOR ENGINE COOLANT LEAKAGE (See  ENGINE COOLANT (2ZZ-GE)  ) 
  75. CHECK FOR ENGINE OIL LEAKAGE 
  76. CHECK FOR EXHAUST GAS LEAKAGE 
  77. INSTALL CYLINDER HEAD COVER NO. 2 

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

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