Section 12 (Engine Mechanical Timing Chain Sub-Assembly - 2ZZ-GE): Replacement

1. Remove the 3 bolts, the nut and the cylinder head cover No. 2.

1. Disconnect engine wire harness.
2. Remove the bolt and wiring harness clamp bracket.
   Fig 1: Removing Wiring Harness Clamp Bracket

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1. Remove the 2 nuts installing the suction hose sub-assy.
2. Disconnect the suction hose sub-assy.
   Fig 2: Disconnecting Suction Hose Sub-Assembly

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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 3: Turning Drive Belt Tensioner To Remove Belt

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1. Disconnect the ignition coil connectors, oil control valve and crankshaft position sensor connector.
2. Remove the bolt and nut for the earth and put the engine wiring side.

1. Remove the 4 bolts and the 4 ignition coils.
   Fig 4: Removing Ignition Coils

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1. Disconnect the fuel hose clamp and 2 PCV hoses from the cylinder head cover.
2. Remove the 2 nuts, bolt and disconnect the No. 3 ventilation hose from the No. 1 ventilation pipe.
3. Disconnect the ventilation No. 1 tube and gasket.
   Fig 5: Disconnecting No. 3 Ventilation Hose From No. 1 Ventilation Pipe

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4. Remove the 8 bolts, wire harness protector, cylinder head cover and gasket.
5. Remove the O-ring from the cylinder head cover.
   Fig 6: Removing Cylinder Head Cover

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1. Set the jack to the engine.
   NOTE: Place a wooden block between the jack and engine.
   Fig 7: Placing Wooden Block Between Jack & Engine

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2. Remove the 5 bolts, 2 nuts and engine mounting insulator sub-assy RH.
   Fig 8: Removing Engine Mounting Insulator Sub-Assembly RH

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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.
   Fig 9: Aligning Timing Chain Gears

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

1. Using SST, remove the pulley bolt.

   SST 09213-7001 1 (09213-70020), 09330-00021

   Fig 10: Removing Pulley Bolt Using SST

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2. Using SST, remove the crankshaft pulley.

   SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021, 09957-04010)

   Fig 11: Removing Crankshaft Pulley Using SST

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1. Using SST, remove the water pump pulley.

   SST 09960-10010

   Fig 12: Removing Water Pump Pulley Using SST

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1. Remove the 6 bolts and water pump.
   Fig 13: Removing Water Pump Assembly

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1. Remove the 4 bolts and the engine mounting bracket.
   Fig 14: Removing Engine Mounting Bracket

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1. Remove the 2 nuts and chain tensioner assy No. 1.
   Fig 15: Removing Chain Tensioner Assembly No. 1

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   NOTE: Be sure not to revolve the crankshaft without the chain tensioner.

1. Remove the 12 bolts.
2. Using a Torx wrench socket (E8), remove the stud bolt.
3. Remove the timing chain cover and 2 gaskets.
   NOTE: Be careful no tot damage the contact surfaces of the timing chain cover, cylinder head and cylinder block.
   Fig 16: Removing Timing Chain Cover

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1. Using a screwdriver, remove the oil seal.
   Fig 17: Removing Oil Seal Using A Screwdriver

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1. Remove the bolt and the chain tensioner slipper.

1. Remove the 2 bolts and chain vibration damper No. 1.

1. Remove the timing chain with the crankshaft timing gear plying screwdrivers as shown in the illustration.
Fig 18: 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 19: Aligning Point Marks Of Camshaft Timing Sprockets

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   2. Turn the crankshaft and set the set key on the crankshaft upward.
      Fig 20: Aligning Crankshaft Set Key

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2. Install the timing chain on the crankshaft timing sprocket with the yellow mark link aligned with the timing mark on the crankshaft timing sprocket.
   NOTE: Three yellow color links are on the chain.
   Fig 21: Aligning Timing Chain With Crankshaft Timing Sprocket

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3. Using a SST, install the sprocket.

   SST 09223-22010

   Fig 22: Installing Sprocket Using SST

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4. Install the timing chain on the camshaft timing sprockets with the yellow mark links aligned with the timing marks on the camshaft timing sprockets.
   Fig 23: Aligning Timing Chain With Camshaft Timing Sprocket

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1. Install the chain vibration damper No. 1 with the 2 bolts.

   Torque: 21 N.m (214 kgf.cm, 15 ft.lbf) 

1. Install the chain tensioner slipper with the bolt.
   Fig 24: Installing Chain Tensioner Slipper

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   Torque: 21 N.m (214 kgf.cm, 15 ft.lbf) 

2. Check that the chain tensioner slipper moves is caught on the cylinder head stopper.
   NOTE: Do not turn the crankshaft.

1. Install the plate with the "F" mark facing forward.
   Fig 25: Installing Plate With F Mark Facing Upward

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

   SST 09223-22010

   NOTE: Keep the lip off foreign materials.
   Fig 26: Using SST To Install New Oil Seal

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1. Remove any old packing (FIPG) material and 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 a 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.
     Fig 27: Installing Gaskets To Timing Chain Cover

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2. Apply seal packing to the timing chain cover an shown in the illustration.

   Seal packing: 

   Part No. 08826-00100 or equivalent 

   • Install a nozzle that has been cut to a 1.5 mm opening.
     NOTE: Avoid applying an excessive amount to the surface.
     • Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
     • Immediately remove nozzle from the tube and reinstall cap.
3. Install the 2 gaskets to the timing chain cover an shown in the illustration.
4. Apply seal packing to 4 locations an shown in the illustration.
   Fig 28: Applying Seal Packing To Locations

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   Seal packing: 

   Part No. 08826-00080 or equivalent 

   • Install a nozzle that has been cut to a 4-5 mm (0.16-0.20 in.)opening.
   NOTE: Avoid applying an excessive amount to the surface.
   • Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
   • Immediately remove nozzle from the tube and reinstall cap.
   NOTE: Do not put into engine oil within 2 hours after installing.
5. Install the timing chain cover, with the 12 bolts and nut.

   Torque: 

   21 N.m (214 kgf.cm, 15 ft.lbf) (M8) 

   11 N.m (112 kgf.cm, 8 ft.lbf) (M6) 

6. Install the stud bolt.

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

1. Check the O-ring is clean, and set the hook as shown in the illustration.
   Fig 29: Setting Chain Tensioner Hook

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

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

   NOTE: When installing the tensioner, set the hook again if the hook release the plunger.
   Fig 30: Installing Chain Tensioner Assembly

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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 pulley bolt.

   SST 09213-7001 1 (09213-70020), 09330-00021

   Torque: 118 N.m (1,203 kgf.cm, 87 ft.lbf) 

   Fig 31: Installing Pulley Bolt Using SST

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3. Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook.
   Fig 32: Turning Crankshaft Counterclockwise To Release Plunger Knock Pin

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4. Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.
   Fig 33: Turning Crankshaft Clockwise To Check Plunger Operation

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

1. Install the engine mounting bracket with the 4 bolts.

   Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 

   Fig 34: Installing Engine Mounting Bracket

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1. Place a new O-ring on the timing chain cover.
2. Install the water pump with the 6 bolts.
   Fig 35: Installing Water Pump & Bolts

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

   NOTE: Each bolt length is indicated in the illustration.
   BOLTS LENGTH SPECIFICATION
   
   

   Bolt A	35 mm (1.38 in.)
   Bolt B	28 mm (1.10 in.)

1. Using SST, install the water pump pulley.
   Fig 36: Installing Water Pump Pulley Using SST

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   SST 09960-10010 (09962-01000, 09963-00600)

   Torque: 15 N.m (153 kgf.cm, 11 ft.lbf) 

Torque: 

Nut: 29 N.m (296 kgf.cm, 21 ft.lbf) 

Bolt: 100 N.m (1,020 kgf.cm, 74 ft.lbf) 

1. Install the engine mounting insulator sub-assy RH with the 5 bolts and the 2 nuts.

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

   Fig 37: Installing Engine Mounting Insulator Sub-Assembly RH

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1. Remove any old packing (FIPG) material.
   NOTE: When FIPG on the head cover gasket side cannot be eliminated completely, replace the gasket.
2. Apply seal packing to 2 locations as shown in the illustration.
   Fig 38: Applying Seal Packing To Specified Locations

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   Seal packing: 

   Part No. 08826-00080 or equivalent 

3. Install the cylinder head cover gasket to the cylinder head cover.
   NOTE: Part must be assembled within 3 minutes of application. Otherwise the material must be remove and reapplied.
4. Install the new spark plug tube gasket and a new O-ring to the cylinder head cover.
   Fig 39: Installing New Spark Plug Tube Gaskets & O-Ring

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5. Install the cylinder head cover and wire harness protector with the 9 bolts. Uniformly tighten the bolts, in the several passes, in the sequence shown.
   Fig 40: Installing Cylinder Head Cover

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   Torque: 10 N.m (102 kgf.cm, 7 ft.lbf) 

6. Connect the 2 PCV hoses to the cylinder head cover.
7. Install a new gasket and No. 1 ventilation pipe with 2 nuts and bolt.
   Fig 41: Installing Ventilation Pipe

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   Torque: 

   Nut 10 N.m (102 kgf.cm, 7 ft.lbf) 

   Bolt 24 N.m (245 kgf.cm, 18 ft.lbf) 

8. Connect the No. 3 ventilation hose to the No. 1 ventilation pipe.

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

Fig 42: Installing Ignition Coil Assemblies

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Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf) 

Fig 43: Installing Suction Hose Sub-Assembly

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Torque: 10 N.m (102 kgf.cm, 7 ft.lbf) 

Fig 44: Installing Wire Harness Clamp

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