Part 1

CHAIN SUB-ASSEMBLY (2AZ-FE)
REPLACEMENT





NOTICE: When disconnecting the battery negative terminal, initialize the system(s) shown after the terminal is reconnected.

1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE HOOD SUB-ASSEMBLY
3. REMOVE FRONT WHEEL RH
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE ENGINE UNDER COVER LH
6. REMOVE FRONT FENDER APRON SEAL RH





7. REMOVE ENGINE COVER SUB-ASSEMBLY NO.1
a. Remove the 2 nuts, then remove the engine cover No. 1.
8. DRAIN ENGINE OIL
9. REMOVE EXHAUST PIPE ASSEMBLY FRONT
10. REMOVE FAN AND GENERATOR V-BELT
SST 09249-63010
11. REMOVE GENERATOR ASSEMBLY
12. SEPARATE VANE PUMP ASSEMBLY
SST 09249-63010





13. REMOVE ENGINE MOUNTING INSULATOR RH
a. Remove the bolt and radiator reserve tank.





b. Separate the vane pump oil reservoir from the oil reservoir bracket No. 1.

NOTICE: Do not disconnect the 2 hoses.





c. Remove the 2 bolts, then separate the return tube.





d. Remove the 2 bolts and oil reservoir bracket No. 1.





e. Remove the bolt, then separate the wire harness protector.
f. Disconnect the 2 clamps of the engine wire.





g. Place a transmission jack underneath the engine, then put a wooden block on the jack.





h. Remove the bolt and nut, then separate the engine mounting insulator FR from the engine mounting bracket FR.





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

NOTICE: Do not apply excessive force to the return tube when removing the engine mounting insulator RH.

HINT: Keep clearance by lowering the engine using the transmission jack when removing the engine mounting insulator RH.

14. REMOVE IGNITION COIL ASSEMBLY





15. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
a. Disconnect the 2 ventilation hoses from the cylinder head cover.





b. Disconnect the clamp of the engine wire.
c. Remove the bolt, then disconnect the engine wire.





d. Remove the 8 bolts and 2 nuts, then remove the cylinder head cover.





16. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
a. Lift the engine upward using the transmission jack, then remove the bolt and nut shown in the illustration.

NOTICE: Do not lift the engine more than necessary.

b. Remove the V-ribbed belt tensioner.
17. REMOVE CRANKSHAFT POSITION SENSOR





18. REMOVE OIL PAN SUB-ASSEMBLY
a. Install the engine hanger No. 1 and No. 2 with the bolts as shown in the illustration.
Torque: 38 Nm (387 kgf-cm, 28 ft. lbs.)





Parts No.

b. Using a chain block and sling device, hold the engine.





c. Remove the 12 bolts and 2 nuts.





d. Insert the blade of SST between the crankcase, chain cover and oil pan, then cut off the applied sealer and remove the oil pan.
SST 09032-00100

NOTICE: Be careful not to damage the contact surface of the crankcase, chain cover and oil pan.





19. 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 each timing mark of the camshaft timing gears is aligned with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration.
If not, turn the crankshaft by 1 revolution (360°) to align the timing marks as above.





20. REMOVE CRANKSHAFT PULLEY
a. Using SST, fix the pulley and loosen the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021





b. Using SST and the pulley bolt, remove the crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)





21. REMOVE CHAIN TENSIONER ASSEMBLY NO.1
a. Remove the bolt.
b. Disconnect the wire harness protector clamp.





c. Remove the 2 nuts, chain tensioner and gasket.

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





22. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
a. Using a Torx socket E10, remove the stud bolt for the V ribbed belt tensioner.





b. Remove the 14 bolts and 2 nuts.
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.





23. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
a. Using a screwdriver and hammer, tap out the oil seal.
24. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1





25. REMOVE TIMING CHAIN GUIDE
a. Remove the bolt and timing chain guide.
26. REMOVE CHAIN TENSIONER SLIPPER
a. Remove the bolt and chain tensioner slipper.
27. REMOVE CHAIN SUB-ASSEMBLY
28. REMOVE CHAIN VIBRATION DAMPER NO.1
a. Remove the 2 bolts and chain vibration damper.
29. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET





30. REMOVE NO.2 CHAIN SUB-ASSEMBLY
a. Turn the crankshaft by 90° counterclockwise to align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pomp.





b. Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock in position, then remove the nut.





c. Remove the bolt, then remove the chain tensioner plate and spring.
d. Remove the oil pump drive gear, oil pump drive shaft gear and No. 2 chain.





31. INSTALL NO.2 CHAIN SUB-ASSEMBLY
a. Set the crankshaft key in the left horizontal position.
b. Turn the cutout of the drive shaft to the top.





c. Align the yellow mark links with the timing marks of the each gear as shown in the illustration.
d. Install the gears onto the crankshaft and oil pump shaft with the chain wrapped.
e. Temporarily tighten the oil pump drive shaft gear with the nut.





f. Insert the damper spring into the adjusting hole, then install the chain tensioner plate with the bolt.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)





g. Align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pump.
h. Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock in position, then tighten the nut.
Torque: 29.5 Nm (301 kgf-cm, 22 ft. lbs.)





i. Turn the crankshaft clockwise by 90° to position the crankshaft key upward.
32. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
33. INSTALL CHAIN VIBRATION DAMPER NO.1
a. Install the chain vibration damper with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)





34. INSTALL CHAIN SUB-ASSEMBLY
a. Set the No. 1 cylinder to TDC/compression.
1. Turn the camshafts with a wrench on the hexagonal lobe to align the timing marks of the camshaft timing gear with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration.





2. Using the crankshaft pulley bolt, turn the crankshaft to position the key on the crankshaft upward.





b. Install the chain onto the crankshaft timing gear with the gold or orange mark link aligned with the timing mark on the crankshaft timing gear.





c. Using SST, tap in the crankshaft timing gear.
SST 09309-37010





d. Align the gold or yellow mark links with each timing mark located on the camshaft timing gears, then install the chain.