Chain Sub-Assembly

CHAIN SUB-ASSEMBLY (2GR-FE)














COMPONENTS

REPLACEMENT

HINT: Refer to CAMSHAFT (RH BANK) or CAMSHAFT (LH BANK) for the replacement procedure of the No.2 chain.

1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
2. REMOVE ENGINE WIRE
3. REMOVE FRONT FRAME ASSEMBLY
4. REMOVE STARTER ASSEMBLY
5. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY





6. REMOVE OIL LEVEL GAUGE GUIDE SUB-ASSEMBLY
a. Remove the oil level gauge.
b. Remove the bolt and pull out the oil level gauge guides No.1 and No.2.
c. Remove the 2 O-rings from the oil level gauge guide.
7. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY
SST 09213-7001 (09213-70020), 09330-00021
8. FIX ENGINE ASSEMBLY
a. Fix the engine onto the engine stand.
9. REMOVE IDLER PULLEY SUB-ASSEMBLY NO.2
a. Remove the bolt and idler pulley.
10. REMOVE ENGINE MOUNTING BRACKET RH





11. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
a. Remove the 5 bolts and V-ribbed belt tensioner.
12. REMOVE WATER PUMP PULLEY
SST 09960-10010 (09962-01000, 09963-00700)
13. REMOVE TIMING GEAR COVER NO.2
14. REMOVE ENGINE MOUNTING STAY NO.2 RH
15. REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 LH
16. REMOVE WATER INLET HOUSING
17. REMOVE CRANKSHAFT PULLEY





a. Using SST, hold the crankshaft pulley and loosen the pulley set bolt.
SST 09213-70011 (09213-70020), 09330-00021





b. Using the pulley set bolt and SST, remove the crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
18. REMOVE OIL PAN SUB-ASSEMBLY NO.2





a. Remove the 16 bolts and 2 nuts.





b. Insert the blade of SST between the oil pans. Cut through the applied sealer and remove the oil pan sub-assembly No.2.
SST 09032-00100

NOTICE: Be careful not to damage the contact surfaces of the oil pans.





19. REMOVE OIL STRAINER SUB-ASSEMBLY
a. Remove the bolt, 2 nuts and oil strainer and gasket.





20. REMOVE OIL PAN SUB-ASSEMBLY
a. Remove the 16 bolts and 2 nuts.

HINT: Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage.





b. Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver.

NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pan.

HINT: Tape the screwdriver tip before use.





c. Remove the O-rings from the oil pump.
21. REMOVE INTAKE AIR SURGE TANK
22. REMOVE IGNITION COIL ASSEMBLY
23. REMOVE OIL PIPE NO.1
24. REMOVE OIL PIPE NO.2
25. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH
26. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
27. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
28. REMOVE TIMING CHAIN COVER OIL SEAL
29. SET NO.1 CYLINDER TO TDC/COMPRESSION





a. Temporarily tighten the pulley set bolt.
b. Set the timing mark on the crank angle sensor plate to the RH block bore center line. (TDC/compression)





c. Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing caps as shown in the illustration.
If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks as above.





30. REMOVE CHAIN TENSIONER ASSEMBLY NO.1
a. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
b. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the stopper plate's hole.
c. Remove the 2 bolts and chain tensioner.
31. REMOVE CHAIN TENSIONER SLIPPER
32. REMOVE CHAIN SUB-ASSEMBLY





a. Turn the crankshaft 10° counterclockwise to loosen the chain of the crankshaft timing gear.
b. Remove the chain from the crank timing gear and place it on the crankshaft.





c. Turn the camshaft timing gear assembly on the RH bank clockwise (approximately 60°) and set it as shown in the illustration. Be sure to loosen the chain between the center banks.
d. Remove the chain sub-assembly.
33. INSTALL CHAIN SUB-ASSEMBLY





a. Align the mark plate and timing mark as shown in the illustration and install the chain.

NOTICE: Do not pass the chain over the crankshaft, just put it on it.

HINT: The chain mark plate is orange.





b. Turn the camshaft timing gear assembly on the RH bank counterclockwise to tighten the chain between banks.





c. Align the mark plate and timing mark as shown in the illustration and install the chain onto the crankshaft timing gear.

HINT: The chain mark plate is yellow.

d. Temporarily tighten the pulley set bolt.
34. INSTALL CHAIN TENSIONER SLIPPER
35. INSTALL CHAIN TENSIONER ASSEMBLY NO.1





a. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
b. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.





c. Install the chain tensioner No.1 with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)





d. Remove the lock pin of chain tensioner assembly No.1. Check that each timing mark is aligned with the crankshaft at the TDC/compression.
e. Remove the pulley set bolt.
36. INSTALL TIMING CHAIN COVER OIL SEAL
SST 09316-60011 (09316-00011)
37. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
38. INSTALL WATER INLET HOUSING
39. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 LH

NOTICE: Install engine mounting bracket front No.1 LH within 15 minutes after apply FIPG to timing chain cover.

40. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
41. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH
42. INSTALL OIL PIPE NO.2
43. INSTALL OIL PIPE NO.1
44. INSTALL IGNITION COIL ASSEMBLY
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
45. INSTALL INTAKE AIR SURGE TANK
46. INSTALL OIL PAN SUB-ASSEMBLY
a. Remove any old packing (FIPG) material. Be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan.





b. Install 2 new O-rings to the oil pump.





c. Apply seal packing in a continuous bead as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent
Seal diameter: 3.0 to 4.0 mm (0.118 to 0.156 inch)

NOTICE:
- Remove any oil from the contact surface.
- Install the crankcase within 3 minutes after applying seal packing.
- Do not start the engine for at least 2 hours after installation.





d. Install the oil pan with the 16 bolts and 2 nuts.
Torque:
10 Nm (102 kgf-cm, 7 ft. lbs.) for bolt A
21 Nm (214 kgf-cm, 15 ft. lbs.) for bolts except A





47. INSTALL OIL STRAINER SUB-ASSEMBLY
a. Install a new gasket and the oil strainer with the bolt and 2 nuts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
48. INSTALL OIL PAN SUB-ASSEMBLY NO.2
a. Remove any old packing (FIPG) material. Be careful not to drop any oil on the contact surfaces of the oil pan and oil pan No.2.





b. Apply seal packing in a continuous bead as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent
Seal diameter: 3.0 to 4.0 mm (0.118 to 0.156 inch)

NOTICE:
- Remove any oil from the contact surface.
- Install the crankcase within 3 minutes after applying seal packing.
- Do not start the engine for at least 2 hours after installation.





c. Install the oil pan No.2 with the 16 bolts and 2 nuts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
d. Install a new gasket and the drain plug.
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)





49. INSTALL CRANKSHAFT PULLEY
a. Using SST, install the pulley set bolt.
SST 09213-70011 (09213-70020), 09330-00021
Torque: 250 Nm (2,549 kgf-cm, 184 ft. lbs.)
50. INSTALL ENGINE MOUNTING STAY NO.2 RH
51. INSTALL TIMING GEAR COVER NO.2
52. INSTALL WATER PUMP PULLEY
SST 09960-10010 (09962-01000, 09963-00700)





53. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
a. Temporarily install the V-ribbed belt tensioner with the 5 bolts.
b. Install the V-ribbed belt tensioner by tightening the bolt 1 and bolt 2 in the order shown in the illustration.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
c. Tighten the other bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)

HINT:
Each bolt length is as follows:
A: 70 mm (2.76 inch)
B: 35 mm (1.38 inch)

54. INSTALL ENGINE MOUNTING BRACKET RH
55. INSTALL IDLER PULLEY SUB-ASSEMBLY NO.2
a. Install the idler pulley with the bolt.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
56. REMOVE ENGINE ASSEMBLY
a. Remove the engine from the engine stand.
57. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY
SST 09213-70011 (09213-70020), 09330-00021





58. INSTALL OIL LEVEL GAUGE GUIDE SUB-ASSEMBLY
a. Install 2 new O-rings to the oil level gauge guide.
b. Apply a light coat of engine oil to the 2 O-rings.
c. Push in the oil level gauge guide end into the guide hole.
d. Install the oil level gauge guide No.1 with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
e. Install the oil level gauge guide No.2 with the bolt.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
f. Install the oil level gauge.
59. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
60. INSTALL STARTER ASSEMBLY
61. INSTALL FRONT FRAME ASSEMBLY
62. INSTALL ENGINE WIRE
63. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE