Timing Chain: Service and Repair
CHAIN SUB-ASSEMBLY (2ZZ-GE)
COMPONENTS
REPLACEMENT
1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. DRAIN COOLANT
3. REMOVE FRONT WHEEL RH
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE FRONT SUSPENSION BAR ASSEMBLY TOWER
6. REMOVE CYLINDER HEAD COVER NO.2
a. Remove the 3 bolts and nut, then remove the cylinder head cover No.2.
7. REMOVE WIRE HARNESS PROTECTOR
8. SEPARATE SUCTION HOSE SUB-ASSEMBLY
9. REMOVE AIR SWITCHING VALVE ASSEMBLY
10. REMOVE FAN AND GENERATOR V BELT
11. REMOVE GENERATOR BRACKET NO.1
12. REMOVE GENERATOR ASSEMBLY
13. REMOVE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
HINT: Hang up the hoses instead of detaching.
14. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY
15. REMOVE CONSOLE PANEL UPPER
16. REMOVE PARKING BRAKE HOLE COVER SUB-ASSEMBLY
17. REMOVE CONSOLE BOX CARPET
18. REMOVE CONSOLE BOX SUB-ASSEMBLY REAR
19. REMOVE EXHAUST PIPE ASSEMBLY FRONT
20. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH
21. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
HINT: Jack the engine up and down to remove the bolt.
22. REMOVE IGNITION COIL ASSEMBLY
23. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
24. REMOVE MANIFOLD STAY
a. Remove the 2 bolts and nut, then remove the manifold stay.
25. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1
26. REMOVE EXHAUST MANIFOLD
a. Remove the 4 bolts and 2 nuts, then remove the exhaust manifold and gasket.
27. REMOVE WATER PUMP PULLEY
SST 09960-10010 (09962-01000, 09963-00600)
28. REMOVE WATER PUMP ASSEMBLY
29. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
a. Remove the 4 bolts and engine mounting bracket.
30. REMOVE CRANKSHAFT POSITION SENSOR
31. 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 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.
32. REMOVE CRANKSHAFT PULLEY
a. Using SST, remove the pulley bolt.
SST 09213-70011 (09213-70020), 09330-00021
b. Using SST, remove the crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021, 09957-04010)
33. REMOVE CHAIN TENSIONER ASSEMBLY NO.1
a. Remove the 2 nuts and chain tensioner assembly No.1.
NOTICE: Do not turn the crankshaft without the chain tensioner.
34. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
a. Remove the 13 bolts and timing chain cover.
b. Remove the 2 gaskets from the timing chain cover.
NOTICE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder head and cylinder block.
35. REMOVE TIMING CHAIN OR BELT COVER OIL SEAL
36. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
37. REMOVE CHAIN TENSIONER SLIPPER
a. Remove the bolt and chain tensioner slipper.
38. REMOVE CHAIN VIBRATION DAMPER NO.1
a. Remove the 2 bolts and chain vibration damper No.1.
39. REMOVE CHAIN SUB-ASSEMBLY
a. Using 2 screwdrivers, pry out the timing chain together 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 sprockets, turn the crankshaft 1/4 revolution to prevent the valves from coming into contact with the pistons.
40. INSTALL CHAIN VIBRATION DAMPER NO.1
a. Install the chain vibration damper No.1 with the 2 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
41. INSTALL CHAIN SUB-ASSEMBLY
a. 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.
(2) Turn the crankshaft to set the set key on the crankshaft upward.
b. 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.
c. Using SST, install the sprocket.
SST 09223-22010
d. Install the timing chain onto the camshaft timing sprockets with the orange mark links aligned with the timing marks on the camshaft timing sprockets.
42. INSTALL CHAIN TENSIONER SLIPPER
a. Install the chain tensioner slipper with the bolt.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
b. Check that the chain tensioner slipper is caught on the cylinder head stopper.
NOTICE: Do not turn the crankshaft.
43. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
a. Install the plate with the F mark facing forward.
44. INSTALL TIMING CHAIN OR BELT COVER OIL SEAL
SST 09223-22010
45. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
a. 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.
b. Apply a continuous bead of seal packing (Diameter 3 mm (0.118 inch)) as shown in the illustration.
Seal packing: THREE BOND 1280 B or equivalent
NOTICE:
^ 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.
c. Install the 2 gaskets onto the timing chain cover as shown in the illustration.
d. Apply a continuous bead of seal packing (Diameter 3 mm (0.118 inch)) as shown in the illustration.
Seal packing: THREE BOND 1280 B or equivalent
NOTICE:
^ 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.
e. Install the timing chain cover with the 13 bolts.
f. Install the stud bolt.
Torque:
21 Nm (214 kgf-cm, 15 ft. lbs.) for (M8) bolt
11 Nm (112 kgf-cm, 8 ft. lbs.) for (M6) bolt
g. Install the stud bolt.
Torque: 9.5 Nm (97 kgf-cm, 84 inch lbs.)
46. 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 engine oil to the chain tensioner, then install it.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
NOTICE: When installing the tensioner, set the hook again if the hook releases the plunger.
47. INSTALL CRANKSHAFT PULLEY
a. Align the pulley set key with the key groove of the pulley, then slide on the pulley.
b. Using SST, install the pulley bolt.
SST 09213-70011 (09213-70020), 09330-00021
Torque: 120 Nm (1,224 kgf-cm, 89 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.
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.
48. INSTALL CRANKSHAFT POSITION SENSOR
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
49. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
a. Install the engine mounting bracket with the 4 bolts.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
50. INSTALL WATER PUMP ASSEMBLY
51. INSTALL WATER PUMP PULLEY
SST09960-10010 (09962-01000, 09963-00600)
52. INSTALL EXHAUST MANIFOLD
a. Install a new gasket and the exhaust manifold with the 4 bolts and 2 nuts.
Torque:
50 Nm (510 kgf-cm, 37 ft. lbs.) for bolt A and nut A
20 Nm (204 kgf-cm, 14 ft. lbs.) for bolt B
53. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
54. INSTALL MANIFOLD STAY
a. Install the manifold stay with the 2 bolts and nut.
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)
55. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
56. INSTALL IGNITION COIL ASSEMBLY
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
57. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
Torque:
29 Nm (296 kgf-cm, 21 ft. lbs.) for nut
100 Nm (1,020 kgf-cm, 74 ft. lbs.) for bolt
58. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH
a. Install the engine mounting insulator RH with the 5 bolts and 2 nuts.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)
59. INSTALL EXHAUST PIPE ASSEMBLY FRONT
60. INSTALL CONSOLE BOX SUB-ASSEMBLY REAR
61. INSTALL CONSOLE BOX CARPET
62. INSTALL PARKING BRAKE HOLE COVER SUB-ASSEMBLY
63. INSTALL CONSOLE PANEL UPPER
64. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY
65. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
66. INSTALL GENERATOR ASSEMBLY
67. INSTALL GENERATOR BRACKET NO.1
68. INSTALL SUCTION HOSE SUB-ASSEMBLY
Torque: 9.8 Nm (100 kgf-cm, 87 inch lbs.)
69. INSTALL AIR SWITCHING VALVE ASSEMBLY
70. INSTALL FRONT SUSPENSION BAR ASSEMBLY TOWER
71. INSTALL FRONT WHEEL RH
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
72. CONNECT BATTERY NEGATIVE TERMINAL
73. ADD COOLANT
74. CHECK FOR ENGINE COOLANT LEAKAGE
75. CHECK FOR ENGINE OIL LEAKAGE
76. CHECK FOR EXHAUST GAS LEAKAGE
77. INSTALL CYLINDER HEAD COVER NO.2
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)