Removal

2AZ-FE ENGINE MECHANICAL: TIMING CHAIN: REMOVAL

REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY Removal
3. REMOVE FRONT WHEEL RH
4. REMOVE ENGINE UNDER COVER LH
5. REMOVE ENGINE UNDER COVER RH
6. REMOVE FRONT FENDER APRON SEAL RH
7. DRAIN ENGINE OIL Replacement
8. REMOVE FRONT EXHAUST PIPE ASSEMBLY
HINT: Removal.

9. REMOVE NO. 2 ENGINE MOUNTING STAY RH Removal
10. REMOVE ENGINE MOVING CONTROL ROD SUB-ASSEMBLY Removal
11. REMOVE NO. 2 ENGINE MOUNTING BRACKET RH Removal
12. REMOVE V-RIBBED BELT Removal
13. REMOVE GENERATOR ASSEMBLY Removal
14. REMOVE VANE PUMP ASSEMBLY Removal
15. REMOVE IGNITION COIL ASSEMBLY Removal
16. DISCONNECT VENTILATION HOSE
17. DISCONNECT NO. 2 VENTILATION HOSE
18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Remove the 2 bolts and disconnect the 2 engine wires.

(b) Remove the 8 bolts, 2 nuts, and cylinder head cover.
19. SET NO. 1 CYLINDER TO TDC/COMPRESSION Removal
20. REMOVE CRANKSHAFT PULLEY Removal
21. REMOVE CRANK POSITION SENSOR Removal
22. REMOVE OIL PAN SUB-ASSEMBLY

(a) Remove the 12 bolts and 2 nuts.

(b) Insert the blade of an oil pan seal cutter between the crankcase and oil pan. Cut through the sealer and remove the oil pan.
NOTICE: Be careful not to damage the contact surfaces of the crankcase, chain cover and oil pan.

23. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Remove the 2 nuts, tensioner and gasket.
NOTICE: Do not turn the crankshaft without the chain tensioner.

24. INSTALL ENGINE HANGERS

(a) Install the No. 1 engine hanger and No. 2 engine hanger with the bolts as shown in the illustration.
Parts No.:

Torque: 38 Nm (387 kgf-cm, 28ft-lbf)
(b) Attach a sling device to the engine hangers and chain block.
25. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(a) Lift the engine upward using the chain block.
NOTICE: Do not lift the engine more than necessary.

(b) Spring type:

(1) Remove the bolt, nut and tensioner.
(c) Except spring type:

(1) Remove the bolt, nut and tensioner.
26. REMOVE ENGINE MOUNTING INSULATOR

(a) Attach the engine chain hoist to the engine hangers.
CAUTION: Do not attempt to hang the engine by hooking the chain to any other part.

(b) Remove the bolt and disconnect the engine mounting insulator FR.

(d) Remove the 2 bolts and disconnect the steering gear return tube clamps from the frame.

(e) Remove the 4 nuts from the engine mounting insulator RH.
(f) Raise the engine and remove the engine mounting insulator RH.
27. REMOVE ENGINE MOUNTING BRACKET RH

(a) Remove the 3 bolts and engine mounting bracket.
28. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY Removal
29. REMOVE TIMING CHAIN CASE OIL SEAL Removal
30. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

(a) Remove the crankshaft position sensor plate.
31. REMOVE CHAIN TENSIONER SLIPPER

(a) Remove the bolt and chain tensioner slipper.
32. REMOVE NO. 1 CHAIN VIBRATION DAMPER

(a) Remove the 2 bolts and chain vibration damper.
33. REMOVE TIMING CHAIN GUIDE

(a) Remove the bolt and timing chain guide.
34. REMOVE CHAIN SUB-ASSEMBLY

(a) Remove the chain sub-assembly.
35. REMOVE CRANKSHAFT TIMING SPROCKET

(a) Remove the crankshaft timing sprocket.
36. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

(a) Turn the crankshaft by 90° counterclockwise to align the adjusting hole of the oil pump drive shaft sprocket with the groove of the oil pump.

(b) Insert a 4 mm diameter pin into the adjusting hole of the oil pump drive shaft sprocket to lock the gear in position, and then remove the nut.

(d) Remove the chain tensioner, oil pump driven sprocket and chain.