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remo

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EM-32
ENGINE MECHANICAL (1GR-FE) - TIMING CHAIN
EM1XK-01

REMOVAL
1. DRAIN ENGINE COOLANT (See page CO-2)
2. DRAIN ENGINE OIL
3. REMOVE BATTERY
4. REMOVE V-BANK COVER
5. REMOVE RADIATOR (See page CO-17)
6. LOOSEN FAN W/FLUID COUPLING
(See page EM-62)
7. REMOVE DRIVE BELT (See page EM-62)
8. REMOVE FAN W/FLUID COUPLING
9. REMOVE AIR CLEANER (See page EM-62)
10. REMOVE INTAKE AIR SURGE TANK
(See page EM-62)
11. REMOVE CYLINDER HEAD COVER
(See page EM-62)
12. REMOVE VVT SENSOR
13. 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.

14. SEPARATE VANE PUMP
(a) Disconnect the P/S oil pressure switch connector.
(b) Remove the 2 bolts, and separate the vane pump.
NOTICE:
Do not hit the pulley to other parts when separating the
vane pump.
HINT:
The vane pump is suspended securely.
A22855 15. REMOVE GENERATOR (See page CH-7)
16. SEPARATE COOLER COMPRESSOR
(See page AC-54)

17. REMOVE V-RIBBED BELT TENSIONER
Remove the 5 bolts and V-ribbed belt tensioner.
18. REMOVE IDLER PULLEY NO.1 AND NO.2

A22856
EM-33
ENGINE MECHANICAL (1GR-FE) - TIMING CHAIN

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

SST
A22857

(b) Using the pulley set bolt and SST, remove the crankshaft
pulley.
SST
SST 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05031)

A22858

20. REMOVE OIL PAN NO.2
(a) Remove the 15 bolts and 2 nuts.

A22859

(b) Insert the blade of SST between the oil pan and oil pan
No. 2, cut off applied sealer and remove the oil pan No.
2.
SST 09032-00100
NOTICE:
S Be careful not to damage the contact surface of the oil
pan and oil pan No. 2.
S Be careful not to damage the oil pan No. 2 flange.
SST
A22860

21. REMOVE OIL STRAINER
Remove the 2 nuts, oil strainer and gasket.

A22861
EM-34
ENGINE MECHANICAL (1GR-FE) - TIMING CHAIN

22. REMOVE OIL PAN
(a) Remove the 4 housing bolts.
(b) Remove the flywheel housing under cover.
Flywheel Housing
Under Cover

A22862

A22863

(d) Using a screwdriver, remove the oil pan by prying be-
tween the oil pan and cylinder block in the sequence
shown.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der block and oil pan.
Pry
(e) Remove the O-ring from the oil pump.
LH Side

RH Side

A22864

23. REMOVE WATER INLET
(a) Disconnect the 2 oil cooler hoses (w/ oil cooler).

A23116
EM-35
ENGINE MECHANICAL (1GR-FE) - TIMING CHAIN

(b) Disconnect the 2 radiator hoses.

A23117

A23118

(d) Remove the 5 bolts and water inlet.
(e) Remove the O-ring from the water outlet pipe.
(f) Remove the gasket from the water pump.

A23119

24. REMOVE TIMING CHAIN COVER
(a) Remove the 24 bolts and 2 nuts.

A23186
EM-36
ENGINE MECHANICAL (1GR-FE) - TIMING CHAIN

(b) Remove the timing chain cover by prying between the tim-
ing chain cover and cylinder head or cylinder block with
a screwdriver.
NOTICE:
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.

A23187

25. SET NO.1 CYLINDER TO TDC/COMPRESSION
Timing Line
(a) Install the crankshaft pulley set bolt, and turn the crank-
shaft to align the crankshaft set key with the timing line of
the cylinder block.

Set Key

A22865

RH Bank Timing Marks (b) Check that the timing marks of the camshaft timing gear
assembly and camshaft timing sprocket are aligned with
the timing marks of the bearing caps as shown in the il-
lustration.
If not, turn the crankshaft 1 complete revolution (360 _) and
align the timing marks as above.
26. REMOVE CHAIN TENSIONER NO.1
NOTICE:
S Never rotate the crankshaft with the chain tensioner
Timing Marks removed.
LH Bank
S When rotating the camshaft with the timing chain re-
moved, rotate the crankshaft counterclockwise 40_
from the TDC first.

Timing Marks A22866
EM-37
ENGINE MECHANICAL (1GR-FE) - TIMING CHAIN

(a) While turning the stopper plate of the tensioner clockwise,
push in the plunger of the chain tensioner as shown in the
Push
illustration.
(b) While turning the stopper plate of the tensioner counter-
clockwise, insert a bar of 3.5 mm (0.138 in.) into the
holes in the stopper plate and tensioner to fix the stopper
plate.
Stopper
Stopper Plate (c) Remove the 2 bolts and chain tensioner.
Plate
A22807 27. REMOVE CHAIN TENSIONER SLIPPER

28. REMOVE IDLE GEAR NO.1
Using a 10 mm hexagon wrench, remove the idle gear shaft No.
2, idle gear No. 1 and idle gear shaft No. 1.
29. REMOVE CHAIN VIBRATION DAMPER NO.2
Remove the 2 chain vibration damper No.2.
30. REMOVE NO.1 TIMING CHAIN
31. REMOVE CRANKSHAFT TIMING SPROCKET

A22867

32. REMOVE NO.2 TIMING CHAIN
(a) While raising the chain tensioner No. 2, insert a pin of
1.0 mm (0.039 in.) into the hole to fix it.

Raise

A22884

(b) Hold the hexagonal portion of the camshaft with a
wrench, and remove the 2 bolts, camshaft timing sprock-
et, camshaft timing gear assembly and timing chain No.2.
NOTICE:
S Be careful not to damage the cylinder head and valve
lifter with the wrench.
S Do not disassemble the camshaft timing gear assem-
bly.
A22903

33. REMOVE CHAIN TENSIONER NO.2
Remove the bolt and chain tensioner No.2.

A22885

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