Toyota 2zz Engine Timing Chain Diagram

How To Remove Crankshaft Timing Pulley On 2000 Toyota Celica Gts.

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Turn the crankshaft 1 revolution (360°) and align the mark as above (See procedure in step 2). Check only the valves indicated as shown. Measure the valve clearance (See procedure in step (a)).

1ZZ-FE:

ADJUST VALVE CLEARANCE

Set the No. 1 cylinder to the TDC/compression (See procedure in step 2).

Place matchmarks on the timing chain and camshaft timing sprockets.

Remove the 2 bolts and chain tensioner.

(d) Remove the camshaft and timing sprocket assemblies (See page EM-42).

(1} 19 camshaft bearing cap bolts

(2) 9 camshaft bearing caps (No. 1 & No. 3)

(3) Exhaust camshaft and timing sprocket assembly

(4) intake camshaft and timing sprocket assembly

HINT:

When disconnect the timing chain from the camshaft timing sprocket, holding the timing chain.

(e) Tie the timing chain with a string as shown in the illustration.

NOTICE:

Be careful not to drop anything inside the timing chain cover.

Do not allow the chain to come into contact with water or dust.

(f) Remove the valve lifters.

(g) Determine the replacement valve lifter size according to these Formula or Charts:

* Using a micrometer, measure the thickness of the removed lifter.

Calculate the thickness of a new lifter so the valve clearance comes within the specified value.

T Thickness of used lifter

A Measured valve clearance

N Thickness of new lifter

Intake: N * T + (A - 0.20 mm (0.008 In.)) Exhaust: N = T + (A — 0.30 mm (0.012 in.))

Select a new lifter with a thickness as close as possible to the calculated values.

HINT:

Lifter are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).

ADJUST VALVE CLEARANCE

(a) Remove the adjusting shim.

(1) Turn the crankshaft so that the cam lobe of camshaft on the adjusting valve points upward.

(2) Using SST, press down the valve.

(3) Using SST, remove the adjusting shim.

(4) Determine the replacement shim size according to these Formula or Charts:

Using dial indicator, measure the thickness of the removed shim.

Calculate the thickness of a new shim so the valve clearance comes within the specified value.

T Thickness of used shim

A Measured valve clearance

N Thickness of new shim intake: N = T+ (A - 0.20 mm (0.008 in.)) Exhaust: NsT+(A-0.40 mm (0.016 in.))

Select a new shim with a thickness as close as possible to the calculated values.

HINT:

Shim are available in 41 size in increments of 0.020 mm (0.0008 in.), from 2.000 mm (0.0787 in.) to 2.800 mm (0.1102 in.).

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1ZZ-FE: Valve Lifter Selection Chart (Exhaust)

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Exhaust valve clearance (Cold): 0.25-0.35 mm (0.010-0.014 in.)

EXAMPLE: The 5.340 mm (0.2102 in.) lifter is insiaüed, and the measured clearance is 0.440 mm (0.0173 in.).

Replace the 5.340 mm (0.2102 in.) lifter with a new No. 48 lifter.

i Thickness	t titer Wo.	Thickness	Lifter No	Thickness
OS ¡5.060(0.1392;	30	5.300(0.2087)	54 5 540(0 2181)
OS 5.080(0.2000}	32	5.320 (0.2094;	56	5.560(0 2183)
1Û I 5,100 (0,2003)	34	5.340 (0.2102;	58	5.580(0.2197)
12 5.120(0.2015)	36	5.360 (0.2110)	60	5.600 (0 2205)
14 5.140(0.2024)	38	5.380 (0.2118)	62 64	5.620(0.2213; 5.640(0.2220)
f6 j 5.160 (0.2031)	40	5.400 (0.2126;
i,S [5.180 (0.2033)	42	6.420(0.2134;	66 68	5.660 (0.222S)
20 j 5.200 (0.2D47;	44	5.440(0.2142)		5.680(0.2236)
22 j 5.22C (0.2055) j 24 ¡5.24C(C.20S3>	5.460(0.2150) 48 ; 5.480 (0.2157)		70 72	5.700(0.2244) 5.720(0.2252)
j 26 5.26D (0.2071 ) j 50 5.500 (0.2165)			74	5.740(0.2260)
i 25 ! 5.280 {0 2C75; : 52 ¡5.520(0 2173;

2ZZ-GE:

Valve Shim Selection Chart (Exhaust)

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Valve Shim Selection Chart (Exhaust)

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New Siiim thickness mm (irr)

Exhaust valve clearance (Cold): 0.35 - 0.45 mm (0.014 - 0.018 in.)

EXAMPLE: The 2.200 mm (0.0862 in.) shim is installed, and the measured clearance is 0.500 mm (0.0197 in.). Replace the 2.300 mm (0.0906 in.) shim with a new No. 30 shim

New Siiim thickness mm (irr)

Sb.rr; No. [	Snim No.	Thickness	Shim ivO.	Thickness
00 ' 2 .000 (0.0787)	28	2.280 '0.0898)	56	2.560 (0.100S)
02 i 2.020(0.0795)	30	2.300 i'0.0906'	58	2.580(0.1015!
04 i 2.040(0.0803)	32	2.320 (0.0913)	60	2.600 ig,,10241
06 ! 2.060 (0.0811;	34 i 2,340 (0.0321)		62	2.620(0.1031)
08 ? 2.080(0.0819)	36 ; 2.360'0.0929)		64	2.640(0.1039)
10 i 2.100 (0.0827)	38 i 2,330 i.0.0937)		fifi	2.660 (0.1047)
(2 I 2.120(0,0835)	40 ■ 2,400 (0,0945) ! 65			2.880(0.1055)
14 I 2.140 if).0543)	42 : 2,420 (0.0953) I 70			2.7ÖÖTÖ. 1063)1
16 ! 2.160(0.0350)	44 i 2.440 (0.0961)		72	2.720 (0.1071)
18 i 2.180(0.0858)	AS I 2.¿60 i0.0969!		IL \ 2.740(0.1079)
20 i 2.200(0 0866) ' 48 ; 2 480 (0.0976)			76 ¡2.760 (0.1037)
22 I 2.220 (0.0S74)	5C i 2.500 (0.0984) 78 j 2.780 <0. S 094)
124 i 2.240(0.0882";	52 '2.520 (0.0922) i 2.800(0.1102)
26 i 2.260 iO.OSSO)	54 i2.540(0.1000; I

REINSTALL CAMSHAFT

(a) Reinstall the valve lifters (See page EM-61).

(b) Align the crankshaft pulley groove with the timing mark "0" of the timing chain cover.

(c) Hold the timing chain, and place the intake camshaft and timing sprocket assembly.

(d) Align the matchmarks on the timing chain and camshaft timing sprocket.

(e) Reinstall the camshaft and timing sprocket assemblies {See page EM-65).

{}) Check that the point marks of the camshaft timing sprockets are in straight line on the timing chain cover surface as shown in the illustration.

(g) Check thai the matchmarks on the timing chain and camshaft timing sprockets.

(h) Install the chain tensioner {See page EM-25).

(i) Recheck the valve clearance {See procedure in step 3).

(j) Check the valve timing (See page EM-25).

7. REINSTALL CYLINDER HEAD COVER {See page EM-25)

IGNITION TIMING INSPECTION

1. WARM UP ENGINE

Allow the engine to warm up to normal operating temperature.

2. CONNECT TOYOTA HAND-HELD TESTER OR OBDH SCAN TOOL

(a) Connect the TOYOTA hand-held tester or OBDII scan tool to the DLC3.

(b) Please refer to the TOYOTA hand-held tester or OBOll scan tool operator's for further details.

3. CONNECT TIMING LIGHT TO ENGINE

4. INSPECT IGNITION TIMING

Using a timing light, check the ignition timing. Ignition timing: 1ZZ-FE:

8 - 12" BTDC @ idle (Transmission in neutral position)

HINT:

After engine rpm is kept at 1,000 - 1,300 rpm for 5 seconds, check that it returns to idle speed.

5. DISCONNECT TIMING LIGHT FROM ENGINE

6. DISCONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL

IDLE SPEED

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INSPECTION

1. INSTALL CONDITIONS

(a) Engine at normal operating temperature

(b) Air cleaner installed

(c) All pipes and hoses of air induction system connected

(d) All vacuum lines properly connected

(e) SFi system wiring connectors fully plugged

(f) Ali operating accessories switched OFF

(g) Ignition timing check correctly {h) Transmission in neutral position (i) Air conditioning switched OFF

2. CONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL

(a) Connect the TOYOTA hand-held tester or OBDII scan tool to the DLC3.

(b) Please refer to the TOYOTA hand-held tester or OBDII scan tool operator's manual for further details.

3. INSPECT iDLE SPEED

(a) Race the engine at 2,500 rpm for approx. 90 seconds.

(b) Check the idle speed.

Idle speed (w/ Cooling fan OFF): 1ZZ-FE

If the idle speed is not as specified, check the IAC valve and air intake system.

4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL

TIMING CHAIN COMPONENTS

1Z2-FE:

RH Engine Mounting Bracket

No. 2 Cylinder Head Cover

Wire Harness Protector

RH Engine Mounting Bracket

No. 2 Cylinder Head Cover

Wire Harness Protector

Crankshaft Timing Sprocket

Chain Vibration Dumper

Crank Angle Sensor Plate

I N'm (kgi cm. ft-lbf) I : Specified torque ♦ Non-teusable part

Crankshaft Timing Sprocket

Chain Vibration Dumper

Crank Angle Sensor Plate

I N'm (kgi cm. ft-lbf) I : Specified torque ♦ Non-teusable part

2ZZ-GE:

Wire Harness Protector

No. 2 Cylinder Head Cover

2ZZ-GE:

Wire Harness Protector

No. 2 Cylinder Head Cover

REMOVAL

1. REMOVE UPPER FRONT FENDER APRON SEAL AND UPPER RADIATOR SUPPORT SEAL

2. DRAIN ENGINE COOLANT

3. REMOVE RH FRONT WHEEL

4. REMOVE RH ENGINE UNDER COVER

5. REMOVE DRIVE BELT AND GENERATOR (See page CH-7)

6. DISCONNECT PS PUMP FROM ENGINE

(a) Disconnect the PS oil pressure switch connector.

(b) Remove the 2 nuts and through bolts, and disconnect the PS pump from the engine (See page SR-24).

HINT:

Put aside the pump and suspend it to the cowl with a string.

7. REMOVE RH ENGINE MOUNTING INSULATOR

(a) Set the jack to the engine. HINT:

Place a wooden block between the jack and engine.

Remove the 4 bolts, 2 nuts and RH engine mounting insulator.

Remove the 5 bolts, 2 nuts and RH engine mounting insulator. 8. 1ZZ-FE:

REMOVE CYLINDER HEAD COVER

(a) Remove the 4 bolts and No. 2 cylinder head cover.

(b) Remove the 4 ignition coils (See page IG-G).

(c) Disconnect the 2 PCV hoses from the cylinder head.

(d) Remove the 9 bolts, 2 seal washers, 2 nuts, cylinder head cover and gasket. 9. 2ZZ-GE:

REMOVE CYLINDER HEAD COVER

(a) Remove the 4 boits and No. 2 cylinder head cover.

(b) Remove the ignition coils (See page SG-6).

(c) Disconnect the 2 PCV hoses from {he cylinder head cover.

(d) Remove the 2 nuts, bolt and disconnect the No. 3 ventilation hose from the No. 1 ventilation pipe.

(e) Remove the No. 1 ventilation pipe and gasket.

(f) Remove the 9 bolts, wire harness protector, cylinder head cover and gasket.

(g) Remove the O-ring from the cylinder head cover.

10. SET NO. 1 CYLINDER TO TDC/COMPRESSION

(a) Turn the crankshaft puiley, and align its groove with timing mark "0" of the timing chain cover.

(b) Check that the point marks of the camshaft timing sprockets are in straight fine on the timing chain cover surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above.

11. REMOVE CRANKSHAFT PULLEY

(a) Using SST and 2 nuts (width: 10 mm (0.25 in.)), remove the pulley bolt.

SST 09213-70010, 09330-00021

(b) Remove the crankshaft puliey.

HINT:

if necessary, remove the pulley with SST.

SST 09950-50012 (09951-05010, 09952-05010, 09953-05020, 09954-05020)

12. DISCONNECT CRANKSHAFT POSITION SENSOR FROM TIMING CHAIN COVER

Remove the 2 bolts and crankshaft position sensor.

13. REMOVE DRIVE BELT TENSIONER Remove the bolt, nut and drive belt tensioner.

14. REMOVE RH ENGINE MOUNTING BRACKET

Remove the 3 bolts and mounting bracket.

Remove the 4 bolts and mounting bracket.

15. REMOVE CHAIN TENSIONER Remove the 2 nuts and chain tensioner.

16. REMOVE WATER PUMP (See page CO-5)

REMOVE TIMING CHAIN COVER

(a) Remove the 11 bolts and nut.

(b) Using atorx wrench socket (E8), remove the stud bolt.

(c) Remove the timing chain cover by prying the portions between the cylinder head and cylinder block with a screwdriver.

NOTICE:

Be careful not to damage the contact surfaces of the timing chain cover, cylinder head and cylinder block.

EM-21

A10390

REMOVE TIMING CHAIN COVER

(a) Remove the 12 bolts.

(b) Using a torx wrench socket (E8), remove the stud bolt.

(c) Remove the timing chain cover and 2 gaskets.

19. REMOVE CRANK ANGLE SENSOR PLATE

20. REMOVE CHAIN TENSJONER SUPPER

Remove the bolt and slipper.

21. REMOVE TIMING CHAIN AND CRANKSHAFT TIMING SPROCKET

If the crankshaft timing sprocket cannot be removed by hand, use 2 screwdrivers.

NOTICE:

Position shop rags as shown to prevent damage.

22. REMOVE CHAIN VIBRATION DAMPER

Remove the 2 bolts and damper.

23. REMOVE VALVE TIMING CONTROL ASSEMBLY AND CAMSHAFT TIMING SPROCKET

Hold the hexagonal head wrench portion of the camshaft with a wrench, and remove the bolt, valve timing controller assembly and timing sprocket, NOTICE:

Be careful not to damage the cylinder head and valve lifter with the wrench.

Do not disassemble the valve timing controller assembly.

INSPECTION

1. INSPECT TIMING CHAIN AND TIMING SPROCKETS

(a) Using a vernier calipers, measure the length of 16 links with the chain dully stretched.

Maximum chain elongation: 122.6 mm (4.827 in.)

If the elongation is greater than maximum, replace the chain. HINT:

Make the same measurements pulling at 3 or more places selected at random.

(b) Wrap the chain around the timing sprocket.

(c) Using a vernier calipers, measure the timing sprocket diameter with the chain.

NOTICE:

Vernier calipers must contact the chain rollers for measuring.

Minimum sprocket diameter (w/ Chain): Camshaft 97.3 mm (3.831 in.) Crankshaft 51.6 mm (2.031 in.) if the diameter is less than minimum, replace the chain and sprockets.

2. INSPECT CHAIN TENSiONER SLIPPER AND VIBRATION DAMPER

Measure the chain tensioner siipper and vibration damper wears.

If the wear is greater than maximum, replace the slipper and/or damper.

3. INSPECT CHAIN TENSIONER

(a) Check that the plunger moves smoothly when the ratchet pawl is raised with your finger.

(b) Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger.

4. INSPECT OIL JET (See page LU-11)

REPLACEMENT

HINT:

There are 2 methods (A and B) to replace the oil seal which are as follows:

REPLACE CRANKSHAFT FRONT OIL SEAL

(a) If timing chain cover is removed from cylinder block.

(1) Using a screwdriver and a hammer, tap out the oil seal.

(2) Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge.

SST 09309-37010

(3) Apply MP grease to the oil seal lip.

(b) If timing chain cover is installed to the cylinder block. {1) Using a knife, cut off the oil seal lip. (2) Using a screwdriver, pry out the oil seal. NOTICE:

Be careful not to damage the crankshaft. Tape the screwdriver tip.

(3) Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover edge. SST 09309-37010

INSTALLATION

1. INSTALL VALVE TIMING CONTROLLER ASSEMBLY AND CAMSHAFT TIMING SPROCKET

(a) Apply engine oil in the range from the tip of the intake camshaft to 16 mm from that tip.

(b) Align the timing mark on the value timing controller assembly with the knock pin, and install the value timing controller assembly to the cam shaft.

NOTICE:

Do not push valve timing controller assembly to the camshaft forcibly when installing it.

(c) Align the knock pin hole in the cam shaft timing sprocket with the knock pin of the cam shaft, and exhaust the sprocket to the cam shaft.

AIM/f

Temporarily install the timing sprocket bolt.

Hold the hexagon wrench head portion of the camshaft with a wrench, and tighten the timing sprocket bolt.

Torque:

1ZZ-FE 45 N-m (460 kgfcm, 33 ft lbt) 2ZZ-GE 54 N m (551 kgf cm, 40 ft lbf)

AIM/f

SET NO. 1 CYLINDER TO TDC/COMPRESSION

Turn the hexagonal wrench head portion of the camshafts, and align the point marks of the camshaft timing sprockets.

Aft*

(b) Using a crankshaft pulley bolt, Turn the crankshaft and set the set key on the crankshaft upward.

1ZZ-FE:

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temwLi/

2ZZ-GE:

3. INSTALL CHAIN VIBRATION DAMPER

Install the damper with the 2 bolts. Torque:

1ZZ-FE 11 N m (113 kgfcm, 8 ft-lbf) 2ZZ-GE 20.5 N-m (209 kgfcm, 15 ft-lbf)

4. INSTALL TIMING CHAIN AND CRANKSHAFT TIMING SPROCKET

(a) Install the timing chain on the crankshaft timing sprocket with the yellow color link aligned with the timing mark on the crankshaft timing sprocket.

HINT:

If necessary, install the sprocket with SST. SST 09223-22010

HINT:

If necessary, install the sprocket with SST. SST 09223-22010

Install the timing chain on the camshaft timing sprockets with the yellow color links aligned with the timing marks on the camshaft timing sprockets.

Install the timing chain on the camshaft timing sprockets with the orange color links aligned with the timing marks on the camshaft timing sprockets.

Cylinder Head Stopper

(d) Check that the tension between the intake camshaft timing sprocket and crankshaft timing sprocket. 5. INSTALL CHAIN TENSION ER SLIPPER

(a) Install the slipper with the bolt. Torque:

1ZZ-FE 18.5 N-m {189 kgf cm, 14 ft lbf) 2ZZ-GE 20.5 N m (209 kgf cm, 15 ft-lfaf)

(b) Check that the slipper moves is caught on the cylinder head stopper.

NOTICE:

DO not turn the crankshaft.

6. INSTALL CRANK ANGLE SENSOR PLATE

Install the plate with the "F" mark facing forward.

A07Z23

INSTALL TIMING CHAIN COVER AND WATER PUMP

(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.

Using a razor blade and a gasket scraper, remove ail the old packing (FSPG) materia! 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.

(b) Apply seal packing to the timing chain cover as shown in the illustration.

Seal packing:

Part No. 08826 - 00100 or equivalent

Install a nozzle that has been cut to a 1.5 mm (0.16 - 0.20 in.) opening.

HINT:

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.

(c) Appiy seal packing to 2 locations as shown in the illustration.

Seal packing:

Part No. 08826 - 00080 or equivalent

Install a noz2le that has been cut to a 1.5 mm (0.16 - 0.20 in.) opening,

HINT:

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.

(d) Install the timing chain cover, O-ring and water pump with the 17 bolts and nut. Uniformly tighten the bolts and nut in several passes.

Torque:

10 mm head:

9 N m (92 kgf-cm, 80 in.lbf) for C 13 N-m (133 kgf cm, 10 ftlbf) for A

12 mm head:

* Pay attention not to wrap the chain and slipper over the chain cover seal line.

• After installing the chain cover, must install the mounting bracket and water pump within 15 minutes.

HINT:

Each bolt length in indicated in the illustration. A 45 mm (1.77 in.) B 35 mm (1.38 in.) C 30 mm (1.18 in.) D 25 mm (0.98 in.)

(e) Using a torx wench socket (E8), install the stud bolt. Torque: 9.3 N-m (95 kgf-cm, 82 in. lbf)

INSTALL TIMING CHAIN COVER AND WATER PUMP

(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces 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 ali the loose material.

Using a non-residue solvent, ciean both sealing surfaces.

(b) Apply seal packing to the timing chain cover as 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.

HINT:

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.

(c) Install the 2 gasket to the timing chain cover as shown in the illustration.

(d) Apply seal packing to 4 locations as shown in the illustration.

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.

HINT:

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 nozzie from the tube and reinstall cap.

(e) Install the timing chain cover, O-ring and water pump with the 19 bolts. Uniformly tighten the bolts in several passes. Torque:

A: 21 N-m (214 kgf cm, 15 ft Ibf) B: 11 N-m (113 kgfcm, 8 ft Ibf) C: 9.0 N-m (92 kgf cm, 80 in-lbf) D: 9.0 N-m (92 kgf cm, 80 in.lbf) NOTICE:

Pay attention not to wrap the chain and slipper over the chain cover seal line.

After install the chain cover, must install the mounting bracket and water pump within 15 minutes.

(f) Using a torx wrench socket (E8), install the stud bolt. Torque: 9.3 N-m (95 kgf cm, 82 in. lbf}

INSTALL RH ENGINE MOUNTING BRACKET

(a) Apply seal packing to threads of the mounting bolt. Seal packing:

Part No. 08826 ~ 00080 or equivalent

HINT;

Do not apply seal packing to 2 or 3 threads of the bolt end.

(b) Install the mounting bracket with the 3 bolts. Torque: 47 N-m (479 kgf cm, 35 ft-lbf)

INSTALL RH ENGINE MOUNTING BRACKET Install the mounting bracket with the 4 boits. Torque: 49 N m (500 kgf cm, 36 ft-lbf)

11. INSTALL DRIVE BELT TENSIONER

(a) Check the appearance before installing the drive belt ten-sioner.

If in case of having the oil leakage, crack, and etc., replace the drive belt tensioner.

(b) Install the drive belt tensioner. Torque:

Bolt

1ZZ-FE 69 N-m (704 kgf cm, 51 ft-lbf) 2ZZ-GE 100 N-m (1,020 kgf cm, 74 ft-lbf) Nut 29 N-m (296 kgf cm, 21 ft-lbf)

(c) Hook the tool on the hexagonal portion of the drive belt tensioner bracket and operate drive belt tensioner 3 times with full stroke.

HINT:

Take 3 seconds or more for 1 full stroke.

12. INSTALL CRANKSHAFT POSITION SENSOR Torque: 9.0 Nm (92 kgfcm, 80 in.ibf)

13. INSTALL CRANKSHAFT PULLEY

(a) Clean the crankshaft pulley inside.

(b) Align the pulley set key with the key groove of the pulley, and slide on the pulley.

(c) Using SSI and 2 nuts (width: 10 mm (0.25 in.), install the pulley bolt.

SST 09213-70010,09330-00021 Torque:

1ZZ-FE 138 N m (1,409 kgf-cm, 102 ftlbf) 2ZZ-GE 120 N m (1,200 kgf cm, 87 ft lbf)

14. INSTALL CHAIN TENSIONER

(a) Check the chain tensioner, (See page EM-16)

(b) Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out.

i Push

i Push

A073I7

(c) Insert the O-ring with your hand until it reaches to the chamfering position and install nut temporally. Then, by tightening the nut, insert the chain tensioner to the installation position.

HINT:

In the case that the hook is released while pushing in, apply the hook again and push the tensioner in. Pay attention not to catch the O-ring as it is built in the chain tensioner previously.

(d) Tighten the 2 nuts.

15. SET CHAIN TENSION

(a) Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook.

(b) Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.

Seal Packing

HINT:

If the plunger does not spring out, press the slipper into the chain tensioner with a screwdriver or your finger so that the hook is released from the knock pin and the plunger springs out.

16. CHECK VALVE TIMING

(a) Turn the crankshaft pulley, and align its groove with timing mark "0" of the timing chain cover.

NOTICE:

Always turn the crankshaft clockwise.

(b) Check that the point marks of the camshaft timing sprockets are in straight line on the timing chain cover surface as shown in the illustration.

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

Seal Packing i

INSTALL CYLINDER HEAD COVER

(a) Remove any old packing (FIPG) material.

(b) Apply seal packing to 2 locations as shown in the illustration.

Seal packing:

Part No. 08826 - 00080 or equivalent

(c) Install the gasket to the cylinder head cover. HINT:

Part must be assembled within 3 minutes of application. Otherwise the material must be remove and reapplied.

(d) Install the cylinder head cover with the 9 bolts, 2 seal washers and 2 nuts.

Uniformly tighten the bolts and nuts, in the several passes, in the sequence shown. Torque: w/o washer

(e) Connect the 2 PCV hoses to the cylinder head cover.

(f) Install the ignition coil (See page IG-7).

INSTALL CYLINDER HEAD COVER

(a) Remove any old packing (FIPG) material. HINT:

When FIPG on the head cover gasket side cannot be eliminated completely, replace the gasket.

(b) Apply seal packing to 2 locations as shown in the illustration.

Seal packing:

Part No. 08826-00080 or equivalent

(c) Install the gasket to the cylinder head cover. HINT;

Part must be assembled within 3 minutes of application. Otherwise the material must be remove and reapplied.

(d) Install a new O-ring to the cylinder head cover.

(e) Install the cylinder head cover and wire harness protector with the9 bolts. Uniformly tighten the bolts, in the several passes, in the sequence shown.

(f) Connect the 2 PCV hoses to the cylinder head cover.

(g) Install a new gasket and No. 1 ventilation pipe with 2 nuts and bolt.

Torque:

Nut 10 N-m (100 kgfcm, 7 ftlbf) Bo» 25 Nm (255 kgf cm, 18 ft lbf)

(h) Connect the No. 3 ventilation hose to the No. 1 ventilation pipe.

(i) Install the ignition coil (See page IG-7).

19. INSTALL RH ENGINE MOUNTING INSULATOR

install the RH engine mounting insulator with the 4 bolts and 2 nuts.

Install the RH engine mounting insulator with the 5 bolts and 2 nuts.

20. INSTALL PS PUMP

(a) Install the PS pump with the 2 through bolts and nuts. Torque: 36 Nm (370 kgf cm, 27 ft lbf)

(b) Install the PS pump pulley with the pulley nut.

(c) Connect the PS oil pressure switch connector.

21. INSTALL GENERATOR AND DRIVE BELT (See page CH-17)

22. INSTALL RH ENGINE UNDER COVER

23. INSTALL RH FRONT WHEEL

24. FILL WITH ENGINE COOLANT (See page CO-2)

25. INSTALL FRONT FENDER APRON SEAL AND UPPER RADIATOR SUPPORT SEAL

26. START ENGINE AND CHECK FOR COOLANT LEAKS

CYLINDER HEAD COMPONENTS

Upper Front Fender Apron Seal

Drive Belt

Upper Radiator Support Seal

Upper Front Fender Apron Seal

Drive Belt

Upper Radiator Support Seal

RH Engine Under Cover

Generator Wire

Generator -Connector

1ZZ-FE: RH Engine Mounting Insulator ^

2ZZ-GE:

RH Engine Mounting Insulator \ »

RH Engine Under Cover

1ZZ-FE:

Upper Heated Insulator

No. 2 Cylinder Head Cover

Upper Heated Insulator

Exhaust Manifold Stay

Exhaust Manifold

Lower Heated Insulator

Wire Harness Protector

Exhaust Manifold Stay

No. 2 Cylinder Head Cover

Wire Harness Protector

Exhaust Manifold

Lower Heated Insulator

Ignition Coil ^ (w/ igniterk ^ f

Spark Plug

♦Exhaust Manifold Gasket

Ignition Coil ^ (w/ igniterk ^ f

PCV Valve Xlfi&w-Tr

Continue reading here: 180 Rsi 2zz Ge Valve Clearance

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