Timing Chain: Service and Repair

CHAIN SUB-ASSEMBLY (1ZZ-FE)











COMPONENTS

REPLACEMENT
1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE FRONT WHEEL RH
3. REMOVE ENGINE UNDER COVER RH





4. REMOVE CYLINDER HEAD COVER NO.2
a. Remove the 2 nuts and 2 clips, then remove the cylinder head cover No.2.
5. DRAIN ENGINE COOLANT
6. REMOVE FAN AND GENERATOR V BELT
7. SEPARATE VANE PUMP ASSEMBLY
8. REMOVE GENERATOR ASSEMBLY





9. REMOVE ENGINE MOUNTING INSULATOR RH
a. Remove the 2 bolts, then remove the oil reservoir bracket No.1.





b. Place a wooden block on a jack underneath the engine.





c. Remove the 4 bolts and 2 nuts, then remove the engine mounting insulator RH.





10. REMOVE IGNITION COIL ASSEMBLY
a. Disconnect the 4 ignition coil connectors.





b. Remove the 2 nuts, then separate the engine wire.





c. Remove the 4 bolts, then remove the 4 ignition coils.





11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
a. Disconnect the ventilation hose from the cylinder head cover.





b. Disconnect the ventilation hose No.2 from the ventilation valve.
c. Remove the 3 clamps of the engine wire from the clamp bracket.





d. Remove the 9 bolts, 2 seal washers, 2 nuts and 3 clamp brackets, then remove the cylinder head cover.





12. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
a. Remove the bolt and nut, then remove the V-ribbed belt tensioner.

HINT: Jack the engine up and down to remove the bolt.





13. REMOVE ENGINE MOUNTING BRACKET RH
a. Remove the 3 bolts, then remove the engine mounting bracket RH.
14. REMOVE WATER PUMP ASSEMBLY





15. SEPARATE CRANKSHAFT POSITION SENSOR
a. Remove the 2 bolts, then separate the crankshaft position sensor.





16. SET NO.1 CYLINDER TO TDC/COMPRESSION
a. Turn the crankshaft pulley until its groove and the timing mark "0" of the timing chain cover are aligned.
b. Check that the point marks of the camshaft timing gears are in a straight line on the timing chain cover surface as shown in the illustration.
If not, turn the crankshaft 1 revolution (360°) to align the marks as above.





17. REMOVE CRANKSHAFT PULLEY
a. Using SST, remove the crankshaft pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
b. Remove the crankshaft pulley from the crankshaft.





18. REMOVE CHAIN TENSIONER ASSEMBLY NO.1
a. Remove the 2 nuts, then remove the chain tensioner.

NOTICE: Do not turn the crankshaft without the chain tensioner.





19. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
a. Remove the 10 bolts and 2 nuts.
b. Using a torx wrench socket (E8), remove the stud bolt.
c. Remove the timing chain cover by prying the portions between the timing chain cover, cylinder head and cylinder block with a screwdriver.

NOTICE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder head and cylinder block.





20. REMOVE TIMING CHAIN OR BELT COVER OIL SEAL
a. Place the timing chain cover on wooden blocks.
b. Using a screwdriver, remove the oil seal.





21. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
a. Remove the crankshaft position sensor plate from the crankshaft.





22. REMOVE CHAIN TENSIONER SLIPPER
a. Remove the bolt, then remove the chain tensioner slipper.





23. REMOVE CHAIN SUB-ASSEMBLY
a. Using 2 screwdrivers, pry out the chain with the crankshaft timing gear, as shown in the illustration.

NOTICE:
^ Use a shop rag to protect the engine.
^ If revolving the camshafts with the chain off the gears, turn the crankshaft 1/4 revolution to prevent the valves from coming into contact with the pistons.





24. INSTALL CHAIN SUB-ASSEMBLY
a. Set the No.1 cylinder to the TDC/compression.
(1) Turn the hexagonal wrench head portion of the camshafts until the point marks of the 2 camshaft timing gears are aligned.





(2) Using a crankshaft pulley bolt, turn the crankshaft to align the timing gear key with the point mark on the oil pump.





b. Install the chain onto the crankshaft timing gear with the yellow mark link aligned with the timing mark on the crankshaft timing gear.





c. Using SST, install the crankshaft timing gear.
SST 09223-22010





d. Install the chain onto the camshaft timing gears with the yellow mark links aligned with the timing marks on the camshaft timing gears.





25. INSTALL CHAIN TENSIONER SLIPPER
a. Install the chain tensioner slipper with the bolt.
Torque: 18.5 Nm (189 kgf-cm, 14 ft. lbs.)





26. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
a. Install the crankshaft position sensor plate with the "F" mark facing forward.
27. INSTALL TIMING CHAIN OR BELT COVER OIL SEAL
a. Apply a light coat of multi-purpose grease to a new oil seal lip.





b. Place the timing chain cover on wooden blocks.
c. Using SST, tap the oil seal in until its surface is flush with the timing chain cover edge.
SST 09223-22010

NOTICE: Keep the lip free of foreign objects.

28. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
a. Remove any old packing material from the contact surface.





b. Apply a continuous bead of seal packing (Diameter 3.5 to 4.5 mm (0.138 to 0.177 inch)) as shown in the illustration.
Seal packing:
Water pump part: Part No.08826-00100 or equivalent
Other part: Part No.08826-00080 or equivalent





NOTICE:
^ Remove any oil from the contact surface.
^ Install the chain cover within 3 minutesof applying seal packing.
^ Do not start the engine for at least 2 hours after installing the chain cover.
^ Be careful to only apply the specified thickness / volume of seal packing in area D.





c. Install the timing chain cover with the 10 bolts and 2 nuts.
Torque:
13 Nm (133 kgf-cm, 10 ft. lbs.) for bolt A and nut A
18.5 Nm (189 kgf-cm, 14 ft. lbs.) for bolt B
d. Using a torx wrench socket (E8), install the stud bolt.
Torque: 9.5 Nm (97 kgf-cm, 84 inch lbs.)





29. INSTALL CHAIN TENSIONER ASSEMBLY NO.1
a. Check that the O-ring is clean, then set the hook as shown in the illustration.
b. Apply a light coat of engine oil to the O-ring.





c. Install the chain tensioner with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

NOTICE:
^ Be careful not to twist the O-ring.
^ When installing the chain tensioner, set the hook again if the hook releases the plunger.





30. INSTALL CRANKSHAFT PULLEY
a. Align the pulley set key with the key groove of the crankshaft pulley, then slide on the crankshaft pulley.
b. Using SST, install the crankshaft pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 138 Nm (1,407 kgf-cm, 102 ft. lbs.)





c. Turn the crankshaft counterclockwise to disconnect the plunger knock pin from the hook.





d. Turn the crankshaft clockwise, then check that the slipper is pushed by the plunger.
If the plunger is not extended, push the slipper into the chain tensioner using a screwdriver so that the hook is released from the knock pin and the plunger can be extended.
31. INSTALL CRANKSHAFT POSITION SENSOR
a. Apply a light coat of engine oil to the O-ring of the crankshaft position sensor.
b. Install the crankshaft position sensor with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
32. INSTALL WATER PUMP ASSEMBLY
33. INSTALL ENGINE MOUNTING BRACKET RH
Torque: 47 Nm (479 kgf-cm, 35 ft. lbs.)





34. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
a. Install the V-ribbed belt tensioner with the bolt and nut.
Torque:
69 Nm (704 kgf-cm, 51 ft. lbs.) for bolt
29 Nm (296 kgf-cm, 21 ft. lbs.) for nut
35. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
a. Remove any old packing material from the contact surface.





b. Apply seal packing to the 2 locations as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the cylinder head cover within 3 minutes of applying seal packing.
^ Do not put in engine oil for at least 2 hours after installation.





c. Install the cylinder head cover and 3 clamp brackets with the 9 bolts, 2 seal washers and 2 nuts.
Torque:
11 Nm (112 kgf-cm, 8 ft. lbs.) for bolt A and nut A
9.0 Nm (92 kgf-cm, 80 inch lbs.) for bolt B
d. Install the 3 clamps of the engine wire onto the clamp bracket.
e. Connect the ventilation hose No.2.
f. Connect the ventilation hose.
36. INSTALL IGNITION COIL ASSEMBLY
a. Install the 4 ignition coils with the 4 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)





b. Install the engine wire with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
c. Connect the 4 ignition coil connectors.





37. INSTALL ENGINE MOUNTING INSULATOR RH
a. Install the engine mounting insulator RH with the 4 bolts and 2 nuts.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)





b. Install the oil reservoir bracket No.1 with the 2 bolts.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)
38. INSTALL GENERATOR ASSEMBLY
39. INSTALL VANE PUMP ASSEMBLY
40. INSTALL FAN AND GENERATOR V BELT
41. ADD ENGINE COOLANT
42. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
43. CHECK FOR ENGINE COOLANT LEAKAGE
44. CHECK FOR ENGINE OIL LEAKAGE
45. INSTALL CYLINDER HEAD COVER NO.2
a. Install the cylinder head cover No.2 with the 2 nuts and 2 clips.
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
46. INSTALL FRONT WHEEL RH
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)