Engine Mechanical Timing Chain Sub-Assembly - 1ZZ-FE: Replacement

1. Remove the 2 nuts, 2 clips and cylinder head cover.

Fig 1: Removing Cylinder Head Cover

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1. Turn the drive belt tensioner clockwise to relieve tension on the belt, and then remove the belt.
2. Carefully return the tensioner to the unloaded position.

Fig 2: Removing Drive Belt Tensioner And Generator V Belt

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1. Remove the PS oil pump reservoir and put it aside.
2. Place a wooden block between the jack and engine, and set the jack, then remove the 4 bolts, the 2 nuts and engine mounting insulator RH.

Fig 3: Placing A Wooden Block Between Jack And Engine

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Fig 4: Removing Engine Mounting

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1. Remove the 5 clamps from the 5 clamp brackets.
2. Disconnect the 4 ignition coil connectors.
   Fig 5: Disconnecting Ignition Coil Connectors

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3. Remove the bolt and nut installing the engine wire.
   Fig 6: Removing Bolt And Nuts

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1. Remove the 4 bolts and 4 ignition coils.

Fig 7: Removing Ignition Coil Assy

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1. Disconnect the ventilation hose from the cylinder head cover.

Fig 8: Disconnecting Ventilation Hose

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1. Disconnect the ventilation hose from the cylinder head cover.

Fig 9: Disconnecting Ventilation Hose-2

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

Fig 10: Removing Cylinder Head Cover Bolts

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1. Turn the crankshaft pulley, and align its groove with timing mark "0" of the timing chain cover.
2. Check that the point marks of the camshaft timing sprocket and VVT timing sprocket are in straight line on the timing chain cover surface as shown in the illustration.

HINT:

If not, turn the crankshaft 1 revolution (360°) and align the marks as above.

Fig 11: Checking Point Marks Of Camshaft And VVT Timing Sprocket

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1. Using SST, remove the pulley bolt.

   SST 09960-10010 (09962-01000, 09963-01000)

2. Remove the crankshaft pulley from the crankshaft.

Fig 12: Removing Crankshaft Pulley

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1. Remove the bolt, nut and V-ribbed belt tensioner.

HINT:

Handle a jack up and down to remove the bolt.

Fig 13: Removing V-Ribbed Belt Tensioner

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1. Remove the 3 bolts and transverse engine mounting bracket.

Fig 14: Removing Transverse Engine Mounting Bracket

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1. Remove the 2 bolts installing the crank position sensor.

Fig 15: Removing Crank Position Sensor

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1. Remove the 2 nuts and chain tensioner.

Fig 16: Removing Chain Tensioner

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1. Remove the 11 bolts and nuts.
2. Using a Torx wrench socket (E8), remove the stud bolt.
3. Remove the timing chain cover by prying the portions between the cylinder head and cylinder block with a screwdriver.

Fig 17: Removing Timing Chain Cover And Bolts

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1. Using a screwdriver, remove the oil seal.

Fig 18: Removing Oil Seal

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1. Remove the bolt and chain tensioner slipper.

1. Remove the timing chain with the crankshaft timing gear plying screwdrivers as shown in the illustration.
Fig 19: Removing Timing Chain With Crankshaft Timing Gear
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1. Set No. 1 cylinder to TDC/compression.
   1. Turn the hexagonal wrench head portion of the camshafts, and align the point marks of the camshaft timing sprockets.
      Fig 20: Aligning Point Marks Of Camshaft Timing Sprockets

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   2. Using a crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward.
      Fig 21: Turning Crankshaft And Set Key On Crankshaft Upward

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2. Install the timing chain on the crankshaft timing sprocket with the yellow color link aligned with the timing mark on the crankshaft timing sprocket.

   HINT:

   Three yellow color links are on the chain.

   Fig 22: Installing Timing Chain On Crankshaft Timing Sprocket

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3. Using SST, install the crankshaft timing sprocket.

   SST 09223-22010

   Fig 23: Installing Crankshaft Timing Sprocket

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4. Install the timing chain on the camshaft timing sprockets with the yellow color links aligned with the timing marks on the camshaft timing sprockets.
   Fig 24: Aligning Timing Marks On Camshaft Timing Sprockets

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1. Install the chain tensioner slipper with the bolt.

   Torque: 19 N.m (194 kgf.cm, 14 ft.lbf) 

1. Install the plate with the "F" mark facing forward.

Fig 25: Installing Crankshaft Position Sensor Plate

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1. Apply MP grease to a new oil seal lip.
2. Using SST, tap in the oil seal until its surface is flush with the timing chain cover edge.

   SST 09223-22010

Fig 26: Installing Timing Gear Cover Oil Seal

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1. Remove any old packing material from the contact surface.
2. Apply seal packing in the shape of bead (Diameter 3.5 mm - 4.5 mm (0.1379 - 0.177 in.)) consequently as shown in the illustration.

   Seal packing: 

   Water pump part No. 08826-00100 or equivalent Other part No. 08826-00080 or equivalent. 

   Fig 27: Applying Seal Packing

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   NOTE:

   • Remove any oil from the contact surface.
   • Install the oil pan within 3 minutes after applying seal packing.
   • Do not put into engine oil within 2 hours after installing.
   Fig 28: Applying Seal Packing

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3. Install the timing chain cover with the 11 bolts and nut.

   Torque: 

   13 N.m (133 kgf.cm, 10 ft.lbf) 

   19 N.m (194 kgf.cm, 14 ft.lbf) 

4. Using a Torx wrench socket (E8), install the stud bolt.

   Torque: 9.5 N.m (97 kgf.cm, 84 in. lbf) 

Fig 29: Installing Timing Chain Cover

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1. Check the O-ring is clean, and set the hook as shown in the illustration.
   Fig 30: Checking O-Ring And Set Hook

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2. Apply engine oil to the chain tensioner and install it with 2 nuts.

   Torque: 9.0 N.m (92 kgf.cm, 80 in. lbf) 

Fig 31: Applying Engine Oil To Chain Tensioner

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1. Install the crank position sensor with the 2 bolts.

   Torque: 9.0 N.m (92 kgf.cm, 80 in. lbf) 

Fig 32: Installing Crank Position Sensor

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1. Install the transverse engine mounting bracket with the 3 bolts.

   Torque: 47 N.m (479 kgf.cm, 35 ft.lbf) 

Fig 33: Installing Transverse Engine Mounting Bracket

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1. Install the V-ribbed belt tensioner with the nut and bolt.

   Torque: 

   Nut 29 N.m (296 kgf.cm, 21 ft.lbf) 

   Bolt 69 N.m (704 kgf.cm, 51 ft.lbf) 

Fig 34: Installing V-Ribbed Belt Tensioner

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1. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
2. Using SST, install the crankshaft pulley bolt.

   SST 09960-10010 (09962-01000, 09963-01000)

   Torque: 138 N.m (1,407 kgf.cm, 102 ft.lbf) 

   Fig 35: Installing Crankshaft Pulley

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3. Turn the crankshaft counter clockwise, and disconnect the plunger knock pin form the hook.
   Fig 36: Disconnect Plunger Knock Pin From Hook

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4. Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.

HINT:

If the plunger does not spring out, press the slipper into the chain tensioner with a screwdriver so that the hook is released from the knock pin and the plunger springs out.

Fig 37: Locating Plunger

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1. Remove any old pacing (FIPG) material.
2. Apply seal packing to 2 locations as shown in the illustration.

   Seal packing: Part No. 08826-00080 or equivalent 

   Fig 38: Applying Seal Packing To 2 Locations

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   NOTE:

   • Remove any oil from the contact surface.
   • Install the cylinder head cover within 3 minutes after applying seal packing.
   • Do not put into engine oil 2 hours after installing.
3. Install the cylinder head cover and 3 cable brackets with the 9 bolts, 2 seal washers and 2 nuts. Uniformly tighten the bolts and nuts, in the several passes.

   Torque: 

   A 11 N.m (112 kgf.cm, 8 ft.lbf) 

   B 9.0 N.m (92 kgf.cm, 80 in. lbf) 

   Fig 39: Installing Cylinder Head Cover

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1. Install the 4 ignition coils with the 4 bolts.

   Torque: 9.0 N.m (92 kgf.cm, 80 in. lbf) 

Fig 40: Installing Ignition Coil Assy

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1. Install the engine wire with the bolt and nut.

   Torque: 9.0 N.m (92 kgf.cm, 80 in. lbf) 

Fig 41: Installing Engine Wire With Bolt & Nut

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1. Install the engine mounting insulator with the 4 bolts and 2 nuts.

   Torque: 52 N.m (530 kgf.cm, 38 ft.lbf) 

Fig 42: Installing Engine Mounting

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1. Install the cylinder head cover with the 2 nuts and 2 clips.

   Torque: 7.0 N.m (71 kgf.cm, 62 in. lbf) 

Fig 43: Installing Cylinder Head Cover

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Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf)