Removal

2AZ-FE ENGINE MECHANICAL: TIMING CHAIN: REMOVAL

TIMING CHAIN: REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

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 NO. 1 ENGINE COVER SUB-ASSEMBLY

(a) Remove the 2 nuts and cover.
8. DRAIN ENGINE COOLANT Testing and Inspection
9. REMOVE FRONT EXHAUST PIPE ASSEMBLY Removal
10. REMOVE FAN AND GENERATOR V BELT Removal
11. REMOVE GENERATOR ASSEMBLY Removal
12. REMOVE VANE PUMP ASSEMBLY
13. REMOVE ENGINE MOUNTING INSULATOR RH

(a) Remove the bolt and radiator reservoir.

(b) Separate the vane pump oil reservoir from the No. 1 oil reservoir bracket.
NOTICE: Do not disconnect the 2 oil reservoir hoses.

(c) Remove the 2 bolts.

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

(e) Remove the bolt of 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, nut and front engine mounting insulator from the front engine mounting bracket.

(i) Remove the 4 bolts, 2 nuts and 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 Removal
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 (labeled A).
(c) Remove the bolt, then disconnect the engine wire (labeled B).

(d) Remove the 8 bolts, 2 nuts and cylinder head cover.
16. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

(a) Lift the engine upward using the transmission jack.
NOTICE: Do not lift the engine more than necessary.

(b) Remove the bolt, nut and V-ribbed belt tensioner.
17. REMOVE CRANKSHAFT POSITION SENSOR Removal
18. REMOVE OIL PAN SUB-ASSEMBLY

(a) Install the No. 1 and No. 2 engine hangers with the bolts.
Torque: 38 Nm (387 kgf-cm, 28 ft-lbf)
Parts No.:

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

(d) Insert the blade of oil pan seal cutter between the crankcase, chain cover and oil pan, then cut off the applied sealer and remove the oil pan.
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
SST: 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 NO. 1 CHAIN TENSIONER ASSEMBLY

(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 COVER SUB-ASSEMBLY

(a) Using an E10 "TORX" socket, 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 NO. 1 CRANKSHAFT POSITION SENSOR PLATE
24. REMOVE TIMING CHAIN GUIDE

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

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

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