Removal

1GR-FE ENGINE MECHANICAL: TIMING CHAIN: REMOVAL

REMOVAL

1. REMOVE BATTERY
2. DRAIN ENGINE COOLANT Service and Repair
3. DRAIN ENGINE OIL Replacement
4. REMOVE POWER STEERING LINK ASSEMBLY (for 2WD)
Refer to the procedures up to "REMOVE POWER STEERING LINK ASSEMBLY" Removal.
5. REMOVE POWER STEERING LINK ASSEMBLY (for 4WD)
Refer to the procedures up to "REMOVE POWER STEERING LINK ASSEMBLY" Removal.
6. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD)
Refer to the procedures up to "REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY" Removal.
7. REMOVE FAN
Refer to the procedures up to "REMOVE FAN PULLEY" Removal.
8. REMOVE GENERATOR ASSEMBLY
Refer to the procedures up to "REMOVE GENERATOR ASSEMBLY" Removal
9. SEPARATE COOLER COMPRESSOR ASSEMBLY Removal

10. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(a) Remove the 5 bolts, then remove the V-ribbed belt tensioner.
11. REMOVE OIL LEVEL GAUGE GUIDE
(a) Remove the oil level gauge.
(b) Remove the bolt and pull out the oil level gauge guide.
(c) Remove the O-ring from the oil level gauge guide.

12. SEPARATE VANE PUMP ASSEMBLY
(a) Disconnect the power steering pressure switch connector.
(b) Remove the 2 bolts, then separate the vane pump.
NOTE: Do not hit the pulley with other parts when separating the vane pump.
HINT: The vane pump is suspended securely.

13. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY

(a) Remove the 2 bolts, then remove the No. 2 idler pulleys.
14. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY

(a) Remove the bolt, then remove the No. 1 idler pulley.
15. REMOVE CRANKSHAFT PULLEY

(a) Using SST, hold the crankshaft pulley and loosen the pulley set bolt.
SST: 09213-54015
91651-60855
SST: 09330-00021

(b) Using the pulley set bolt and SST, remove the crankshaft pulley.
SST: 09950-50013
09951-05010
09952-05010
09953-05020
09954-05031
16. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

(a) Remove the 10 bolts and 2 nuts.

(b) Insert the blade of oil pan seal cutter between the oil pan and No. 2 oil pan, cut off applied sealer and remove the No. 2 oil pan.

NOTICE :
- Be careful not to damage the contact surfaces of the oil pan and No. 2 oil pan.
- Be careful not to damage the No. 2 oil pan flange.

17. REMOVE OIL STRAINER SUB-ASSEMBLY
(a) Remove the 2 nuts, then remove the oil strainer and gasket.
18. REMOVE OIL PAN SUB-ASSEMBLY

(a) Remove the 4 housing bolts.
(b) Remove the flywheel housing under cover.

(d) Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block.
NOTE: Be careful not to damage the contact surfaces of the cylinder block and oil pan.

(e) Remove the O-ring from the oil pump.
19. REMOVE AIR CLEANER ASSEMBLY Removal
20. REMOVE THROTTLE BODY BRACKET Removal
21. REMOVE OIL BAFFLE PLATE Removal
22. REMOVE NO. 1 SURGE TANK STAY Removal
23. REMOVE NO. 2 SURGE TANK STAY Removal
24. REMOVE INTAKE AIR SURGE TANK Removal
25. REMOVE IGNITION COIL ASSEMBLY Removal
26. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Removal
27. REMOVE VVT SENSOR Removal
28. REMOVE WATER INLET Removal
29. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Removal
30. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH Removal
31. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY

(a) Remove the 24 bolts and 2 nuts.

(b) Remove the timing chain cover by prying between the timing chain cover, cylinder head or cylinder block with a screwdriver.
NOTE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder block and cylinder head.

(c) Remove the O-ring from the LH cylinder head.
32. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Replacement
33. SET NO. 1 COMPRESSION TO TDC/COMPRESSION

(a) Using the crankshaft pulley set bolt, turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block.

(b) Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing caps as shown in the illustration.
If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks as above.
34. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY
NOTICE:
- Never rotate the crankshaft with the chain tensioner removed.
- When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first.

(a) While turning the stopper plate of the tensioner upward, push in the plunger of the chain tensioner as shown in the illustration.
(b) While turning the stopper plate of the tensioner downward, insert a bar of dia 3.5 mm (0.138) into the holes in the stopper plate and tensioner to fix the stopper plate.
(c) Remove the 2 bolts, then remove the chain tensioner.
35. REMOVE CHAIN TENSIONER SLIPPER

36. REMOVE NO. 1 IDLE GEAR
(a) Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, No. 1 idle gear and No. 1 idle gear shaft.
37. REMOVE NO. 2 CHAIN VIBRATION DAMPER
(a) Remove the 2 No. 2 chain vibration dampers.
38. REMOVE CHAIN SUB-ASSEMBLY