Toyota Corolla (2004+). Manual

14-103

ENGINE MECHANICAL

- CAMSHAFT

(e) Check that the camshaft timing gear assembly can move

to the retard angle side (the right angle), and is locked at

the most retarded position.

16. INSTALL CAMSHAFT

Painted Link

(a) As shown in the illustration, install the timing chain on the

camshaft timing gear, with the painted links aligned with

the timing marks on the camshaft timing gear.

Timing Mark

A62195

(b) Examine the front marks and numbers and tighten the

bolts in the order shown in the illustration.

Torque: 13 N m (133 kgf cm, 10 ft lbf)

A62196

Painted Link

(c)

Put the camshaft No.2 on the cylinder head with the

painted links of the chain aligned with the timing mark on

the camshaft timing gear.

Timing Mark

A62197

(d) Tighten the camshaft timing gear set bolt temporarily.

A32124

14-104

ENGINE MECHANICAL

- CAMSHAFT

(e) Examine the front marks and numbers and tighten the

bolts in the order shown in the illustration.

Torque: 13 N m (133 kgf cm, 10 ft lbf)

(f)

Install the bearing cap No. 1.

Torque: 23 N m (235 kgf cm, 17 ft lbf)

A62198

(g) Fix the camshaft with a wrench and so on, then tighten the

Fix

camshaft timing gear set bolt.

Tighten

Torque: 54 N m (551 kgf cm, 40 ft lbf)

NOTICE:

Be careful not damage the valve lifter.

A62187

(h) Check the match marks on the timing chain and camshaft

Mark

timing sprockets, and then the alignment of the pulley

Mark

groove with timing mark of the chain cover as shown in the

illustration.

Mark

Timing Chain

Cover Surface

Groove

A62185

(i)

Install chain tensioner.

(1)

Check the O-ring is clean, and set the hook as

Raise

shown in the illustration.

Push

Hook

A62177

14-105

ENGINE MECHANICAL

- CAMSHAFT

(2)

Apply engine oil to the chain tensioner and install it

with the 2 nuts.

Torque: 9.0 N m (92 kgf cm, 80 in lbf)

NOTICE:

When installing the tensioner, set the hook again if the

Push

hook release the plunger.

A62178

(3)

Turn the crankshaft counter clockwise, and discon-

nect the plunger knock pin from the hook.

Disconnect

Hook

Turn

A62180

(4)

Turn the crankshaft clockwise, and check that the

slipper is pushed by the plunger.

HINT:

If the plunger does not spring out, press the slipper into the

chain tensioner with a screwdriver so that the hook is released

from the knock pin and the plunger springs out.

Plunger

Push

Turn

A62181

17. ADJUST VALVE CLEARANCE (See page

14-5)

18. INSTALL V-RIBBED BELT TENSIONER ASSY

(a) Install the V-ribbed belt tensioner with the nut and bolt.

Torque:

Nut 29 N m (296 kgf cm, 21 ft lbf)

Bolt 69 N m (704 kgf cm, 51 ft lbf)

A11858

14-106

ENGINE MECHANICAL

- CAMSHAFT

19. INSTALL CYLINDER HEAD COVER SUB-ASSY

Seal Packing

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

(b) Apply seal packing to 2 locations as shown in the illustra-

tion.

Seal packing: Part No. 08826-00080 or equivalent

NOTICE:

Remove any oil from the contact surface.

Install the cylinder head cover within 3 minutes after

A62182

applying seal packing.

Do not put into engine oil 2 hours after installing.

(c)

Install the cylinder head cover and 3 cable brackets with

the 9 bolts, 2 seal washers and 2 nuts. Uniformly tighten

the bolts and nuts, in the several passes.

Torque:

A 11 Nm (112 kgf cm, 8 ft lbf)

B 9.0 Nm (92 kgf cm, 80 in lbf)

A65687

20. INSTALL IGNITION COIL ASSY

(a) Install the 4 ignition coils with the 4 bolts.

Torque: 9.0 N m (92 kgf cm, 80 in. lbf)

A64023

21. INSTALL ENGINE WIRE

(a) Install the engine wire with the bolt and nut.

Torque: 9.0 N m (92 kgf cm, 80 in. lbf)

A64022

14-107

ENGINE MECHANICAL

- CAMSHAFT

22. INSTALL ENGINE MOUNTING INSULATOR

SUB-ASSY RH

(a) Install engine mounting insulator with the 4 bolts and 2

nuts.

Torque: 52 N m (530 kgf cm, 38 ft lbf)

A64005

23. INSTALL CYLINDER HEAD COVER NO.2

(a) Install the cylinder head cover with the 2 nuts and 2 clips.

Torque: 7.0 N m (71 kgf cm, 62 in. lbf)

A65077

24. CHECK ENGINE OIL LEAK

14-79

ENGINE MECHANICAL

- CHAIN SUB-ASSY

CHAIN SUB-ASSY

140OG-01

COMPONENTS

Fan and Generator V Belt

54 (551, 40)

25 (255, 18)

37 (377, 27)

Vane Pump Assy

Terminal Cap

No. 1

Generator Assy

9.8 (100, 7)

7.0 (71, 62 in. lbf)

Clip

Cylinder Head Cover No. 2

52 (530, 38)

Engine Mounting Insulator RH

52 (530, 38)

Engine Under Cover RH

Clip

N·m (kgf·cm, ft·lbf)

: Specified torque

A64042

14-80

ENGINE MECHANICAL

- CHAIN SUB-ASSY

9.0 (92, 80 in. lbf)

Engine Wire

9.0 (92, 80 in. lbf)

Ignition Coil Assy

Ventilation Hose No. 2

9.0 (92, 80 in. lbf)

11 (112, 8)

Seal Washer

11 (112, 8)

Clamp Bracket

11 (112, 8)

Ventilation Hose

Clamp Bracket

Cylinder Head Cover

Sub-assy

Gasket

N·m (kgf·cm, ft·lbf)

: Specified torque

A64043

14-81

ENGINE MECHANICAL

- CHAIN SUB-ASSY

Transverse Engine

Engine Mounting Bracket

47 (479, 35)

Chain Tensioner Assy No. 1

29 (296, 21)

9.0 (92, 80 in. lbf)

Timing Chain or

V-ribbed Belt

Belt Cover Sub-assy

Tensioner Assy

13 (133, 10) (M6)

19 (194, 14) (M8)

13 (133, 10)

69 (704, 51)

Crankshaft Pulley

138 (1,047, 102)

F Oil Seal

9.0 (92, 80 in. lbf)

9.0 (92, 80 in. lbf1) (L=20)

11 (112, 8) (L=35)

Crank Position Sensor

F O-ring

Water Pump Assy

Chain Sub-assy

Chain Tensioner Slipper

9.5 (97, 84 in. lbf)

19 (194, 14)

Crankshaft timing Sprocket

Crankshaft Position Sensor

Plate No. 1

N·m (kgf·cm, ft·lbf)

: Specified torque

F Non-reusable part

A60625

14-82

ENGINE MECHANICAL

- CHAIN SUB-ASSY

140OH-01

REPLACEMENT

REMOVE ENGINE UNDER COVER RH

DRAIN COOLANT (See page 16-7)

REMOVE FRONT WHEEL RH

REMOVE CYLINDER HEAD COVER NO.2

(a) Remove the 2 nuts, 2 clips and cylinder head cover.

A65077

REMOVE FAN AND GENERATOR V BELT

(a) Turn the V-ribbed belt tensioner slowly clockwise and

loosen it. Then, remove the fan and generator V belt and

put back the V-ribbed belt tensioner little by little and fix

it quietly.

A60622

SEPARATE VANE PUMP ASSY (See page 51-8)

NOTICE:

Do not disconnect the hose.

REMOVE GENERATOR ASSY (See page 19-16)

REMOVE ENGINE MOUNTING INSULATOR

SUB-ASSY RH

(a) Remove the PS oil pump reservoir and put it aside.

(b) Place a wooden block between the jack and engine, and

set the jack, then remove the 4 bolts, the 2 nuts and en-

gine mounting insulator RH.

A01045

A64005

14-83

ENGINE MECHANICAL

- CHAIN SUB-ASSY

DISCONNECT ENGINE WIRE

(a) Remove the 5 clamps from the 5 clamp brackets.

(b) Disconnect the 4 ignition coil connectors.

A64021

(c)

Remove the bolt and nut installing the engine wire.

A64022

10. REMOVE IGNITION COIL ASSY

(a) Remove the 4 bolts and 4 ignition coils.

A64023

11. DISCONNECT VENTILATION HOSE

(a) Disconnect the ventilation hose from the cylinder head

cover.

A65078

12. DISCONNECT VENTILATION HOSE NO.2

(a) Disconnect the ventilation hose from the cylinder head

cover.

A64058

14-84

ENGINE MECHANICAL

- CHAIN SUB-ASSY

13. REMOVE CYLINDER HEAD COVER SUB-ASSY

(a) Remove the 9 bolts, 2 seal washers, 2 nuts, 3 clamp

brackets and cylinder head cover.

A64856

14. SET NO. 1 CYLINDER TO TDC/COMPRESSION

Mark

(a) Turn the crankshaft pulley, and align its groove with timing

Mark

mark ”0” of the timing chain cover.

(b) Check that the point marks of the camshaft timing sprock-

et and VVT timing sprocket are in straight line on the tim-

ing chain cover surface as shown in the illustration.

HINT:

If not, turn the crankshaft 1 revolution (360_) and align the

Mark

marks as above.

Timing Chain

Cover Surface

Groove

A62185

15. REMOVE CRANKSHAFT PULLEY

(a) Using SST, remove the pulley bolt.

SST

09960-10010 (09962-01000, 09963-01000)

(b) Remove the crankshaft pulley from the crankshaft.

SST

A62837

16. REMOVE V-RIBBED BELT TENSIONER ASSY

(a) Remove the bolt, nut and V-ribbed belt tensioner.

HINT:

Handle a jack up and down to remove the bolt.

A11858

14-85

ENGINE MECHANICAL

- CHAIN SUB-ASSY

17. REMOVE WATER PUMP ASSY (See page 16-8)

18. REMOVE TRANSVERSE ENGINE ENGINE

MOUNTING BRACKET

(a) Remove the 3 bolts and transverse engine engine mount-

ing bracket.

A12816

19. REMOVE CRANK POSITION SENSOR

(a) Remove the 2 bolts installing the crank position sensor.

B00086

20. REMOVE CHAIN TENSIONER ASSY NO.1

(a) Remove the 2 nuts and chain tensioner.

NOTICE:

Be sure not to revolve the crankshaft without the chain ten-

sioner.

Push

A62178

21. REMOVE TIMING CHAIN OR BELT COVER

SUB-ASSY

(a) Remove the 11 bolts and nuts.

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

(c)

Remove the timing chain cover by prying the portions be-

tween the cylinder head and cylinder block with a screw-

driver.

NOTICE:

A10076

Be careful no tot damage the contact surfaces of the timing

chain cover, cylinder head and cylinder block.

14-86

ENGINE MECHANICAL

- CHAIN SUB-ASSY

22. REMOVE TIMING GEAR COVER OIL SEAL

(a) Using a screwdriver, remove the oil seal.

A30848

23. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1

24. REMOVE CHAIN TENSIONER SLIPPER

(a) Remove the bolt and chain tensioner slipper.

25. REMOVE CHAIN SUB-ASSY

(a) Remove the timing chain with the crankshaft timing gear

plying screwdrivers as shown in the illustration.

NOTICE:

Put shop rag to protect the engine.

In case of revolving the camshafts with the chain off

the sprockets, turn the crankshaft 1/4 revolution for

valves not to touch the pistons.

A30857

26. INSTALL CHAIN SUB-ASSY

(a) Set No. 1 cylinder to TDC/compression.

(1)

Turn the hexagonal wrench head portion of the

camshafts, and align the point marks of the cam-

shaft timing sprockets.

A10079

(2)

Using a crankshaft pulley bolt, turn the crankshaft

Upward

Set Key

and set the set key on the crankshaft upward.

A62170

14-87

ENGINE MECHANICAL

- CHAIN SUB-ASSY

(b) Install the timing chain on the crankshaft timing sprocket

Yellow

with the yellow color link aligned with the timing mark on

Color Line

the crankshaft timing sprocket.

HINT:

Three yellow color links are on the chain.

Timing Mark

A62171

(c)

Using SST, install the crankshaft timing sprocket.

SST

09223-22010

SST

A62172

Yellow Color Mark

(d) Install the timing chain on the camshaft timing sprockets

with the yellow color links aligned with the timing marks on

the camshaft timing sprockets.

Timing Mark

A62173

27. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the chain tensioner slipper with the bolt.

Torque: 19 N m (194 kgf cm, 14 ft lbf)

28. INSTALL CRANKSHAFT POSITION SENSOR PLATE

NO.1

(a) Install the plate with the ”F” mark facing forward.

A30867

14-88

ENGINE MECHANICAL

- CHAIN SUB-ASSY

29. INSTALL TIMING GEAR COVER OIL SEAL

(a) Apply MP grease to a new oil seal lip.

SST

(b) Using SST, tap in the oil seal until its surface is flush with

the timing chain cover edge.

SST

09223-22010

NOTICE:

Keep the lip off foreign materials.

A62174

30. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSY

Seal Width

4 - 5 mm

(a) Remove any old packing material from the contact sur-

face.

(b) Apply seal packing in the shape of bead (Diameter 3.5

mm - 4.5 mm (0.1379 - 0.177 in.)) consequently as

shown in the illustration.

Seal packing:

Water pump part part No. 08826-00100 or equivalent

Seal Packing

A62175

Other part part No. 08826-00080 or equivalent.

NOTICE:

Remove any oil from the contact surface.

Install the oil pan within 3 minutes after applying seal

packing.

Do not put into engine oil within 2 hours after instal-

ling.

Timing Chain Cover side:

3 (0.118)

4.5

(0.177)

12 (0.472)

6 (0.236)

7 (0.276)

3 (0.118)

Width 4 (0.157)

A - A

B - B

08826-00100 or equivalent

C - C

08826-00080 or equivalent

(mm (in.))

A65676

Toyota Corolla (2004+). Manual - part 90