EM–22 1GR-FE ENGINE MECHANICAL – TIMING CHAIN

REMOVAL
1. REMOVE BATTERY
2. DRAIN ENGINE COOLANT (See page CO-3)
3. DRAIN ENGINE OIL (See page LU-4)
4. REMOVE POWER STEERING LINK ASSEMBLY (for
2WD)
Refer to the procedures up to "REMOVE POWER
STEERING LINK ASSEMBLY" (See page PS-18).
5. REMOVE POWER STEERING LINK ASSEMBLY (for
4WD)
Refer to the procedures up to "REMOVE POWER
STEERING LINK ASSEMBLY" (See page PS-37).
EM 6. REMOVE FRONT DIFFERENTIAL CARRIER
ASSEMBLY (for 4WD)
Refer to the procedures up to "REMOVE FRONT
DIFFERENTIAL CARRIER ASSEMBLY" (See page DF-
20).
7. REMOVE FAN
Refer to the procedures up to "REMOVE FAN PULLEY"
(See page CO-17).
8. REMOVE GENERATOR ASSEMBLY
Refer to the procedures up to "REMOVE GENERATOR
ASSEMBLY" (See page CH-9)
9. SEPARATE COOLER COMPRESSOR ASSEMBLY
(See page ES-420)
10. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(a) Remove the 5 bolts, then remove the V-ribbed belt
tensioner.
11. 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.
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12. SEPARATE VANE PUMP ASSEMBLY

(a) Disconnect the power steering pressure switch
connector.
(b) Remove the 2 bolts, then separate the vane pump.
NOTICE:
Do not hit the pulley with other parts when
separating the vane pump.
HINT:
The vane pump is suspended securely.
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 1GR-FE ENGINE MECHANICAL – TIMING CHAIN EM–23

13. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY

(a) Remove the 2 bolts, then remove the No. 2 idler
pulleys.

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14. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY

(a) Remove the bolt, then remove the No. 1 idler pulley.

EM

“DOUBLE”
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15. REMOVE CRANKSHAFT PULLEY

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

SST
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(b) Using the pulley set bolt and SST, remove the
crankshaft pulley.
SST SST 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05030)

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16. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

(a) Remove the 10 bolts and 2 nuts.

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 EM–24 1GR-FE ENGINE MECHANICAL – TIMING CHAIN

(b) Insert the blade of SST between the oil pan and No.
2 oil pan, cut off applied sealer and remove the No.
2 oil pan.
SST 09032-00100
NOTICE:
• Be careful not to damage the contact
surfaces of the oil pan and No. 2 oil pan.
• Be careful not to damage the No. 2 oil pan
SST flange.
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17. REMOVE OIL STRAINER SUB-ASSEMBLY

(a) Remove the 2 nuts, then remove the oil strainer and
gasket.

EM

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18. REMOVE OIL PAN SUB-ASSEMBLY

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

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(c) Remove the 17 bolts and 2 nuts.

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(d) Using a screwdriver, remove the oil pan by prying

between the oil pan and cylinder block.
NOTICE:
Be careful not to damage the contact surfaces of
the cylinder block and oil pan.
(e) Remove the O-ring from the oil pump.
19. REMOVE AIR CLEANER ASSEMBLY (See page ES-
Pry
429)
G036806E01 20. REMOVE THROTTLE BODY BRACKET (See page
FU-11)
1GR-FE ENGINE MECHANICAL – TIMING CHAIN EM–25

21. REMOVE OIL BAFFLE PLATE (See page FU-11)

22. REMOVE NO. 1 SURGE TANK STAY (See page FU-11)
23. REMOVE NO. 2 SURGE TANK STAY (See page FU-12)
24. REMOVE INTAKE AIR SURGE TANK (See page FU-
12)
25. REMOVE IGNITION COIL ASSEMBLY (See page IG-8)
26. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE
ASSEMBLY (See page ES-414)
27. REMOVE VVT SENSOR (See page ES-417)
28. REMOVE WATER INLET (See page CO-8)
29. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(See page EM-40) EM
30. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
LH (See page EM-40)
31. REMOVE TIMING CHAIN OR BELT COVER SUB-
ASSEMBLY
(a) Remove the 24 bolts and 2 nuts.

G036303E01

(b) Remove the timing chain cover by prying between

the timing chain cover, 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.
32. REMOVE TIMING GEAR CASE OR TIMING CHAIN
CASE OIL SEAL (See page EM-163)

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 EM–26 1GR-FE ENGINE MECHANICAL – TIMING CHAIN

33. SET NO. 1 COMPRESSION TO TDC/COMPRESSION

Timing Line
(a) Using the crankshaft pulley set bolt, turn the
crankshaft to align the crankshaft set key with the
timing line of the cylinder block.
Set Key

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(b) Check that the timing marks of the camshaft timing

Bank 1: Timing Marks
gears are aligned with the timing marks of the
bearing caps as shown in the illustration.
If not, turn the crankshaft 1 complete revolution
EM (360°) and align the timing marks as above.
34. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY
NOTICE:
• Never rotate the crankshaft with the chain
tensioner removed.
• When rotating the camshaft with the timing chain
Bank 2: Timing Marks removed, rotate the crankshaft counterclockwise
40° from the TDC first.

Timing Marks
G036290E06

(a) While turning the stopper plate of the tensioner

upward, push in the plunger of the chain tensioner
as shown in the illustration.
Push (b) While turning the stopper plate of the tensioner
downward, insert a bar of φ 3.5 mm (0.138) into the
holes in the stopper plate and tensioner to fix the
stopper plate.
(c) Remove the 2 bolts, then remove the chain
Stopper Plate Stopper Plate tensioner.
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35. REMOVE CHAIN TENSIONER SLIPPER
36. REMOVE IDLE SPROCKET ASSEMBLY
(a) Using a 10 mm hexagon wrench, remove the No. 2
idle gear shaft, No. 1 idle gear and No. 1 idle gear
shaft.
37. REMOVE NO. 2 CHAIN VIBRATION DAMPER
(a) Remove the 2 No. 2 chain vibration dampers.
38. REMOVE CHAIN SUB-ASSEMBLY

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