Scion 2005-06

Timing Chain Cover, Chain & Sprockets

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Removal & Installation



1.5L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Support the engine with a suitable jack.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Right-hand front wheel
     
    Ignition coil
     
    Ventilation hoses from the cylinder head cover
     
    Cylinder head cover
     
    Accessory drive belts
     
    Alternator
     
    Right-hand engine undercover
     
    Water pump
     

  10.  
  11. Set the No. 1 cylinder to TDC.

    Click image to see an enlarged view

    Fig. Align the timing marks on the camshaft timing gears and timing chain to ensure the No. 1 cylinder is at TDC compression.

  12.  
  13. Using Special Tool 09213-58012, remove the crankshaft pulley bolt.
  14.  
  15. Remove the crankshaft pulley. Use Special Tool 09950-50013 and the pulley bolt if necessary.

    Click image to see an enlarged view

    Fig. Remove crankshaft pulley with Special Tool 09213-58012 and 09950-50013.

  16.  
  17. Remove or disconnect the following:
    NOTE
    Be careful not to damage the contact surfaces of the cover, cylinder head and engine block when prying the cover.



    Camshaft timing oil control valve assembly
     
    Crankshaft position sensor
     
    Right-hand engine mount
     
    Front cover
     



    Oil pump seal
     
    Timing chain tensioner
     
    Timing chain tensioner slipper
     
    Timing chain vibration damper
     
    Timing chain
     

  18.  

To install:

  1. Set the crankshaft at 40-140° ATDC. Set the cams of intake and exhaust timing sprockets at 20° ATDC. Reset the crankshaft to 20 ° ATDC.
  2.  
  3. Install the chain vibration damper with the 2 bolts. Tighten to 80 inch lbs. (9 Nm).
  4.  
  5. Align the matchmarks of the camshaft timing sprocket, the camshaft timing gear and the crankshaft timing sprocket with each mark plate (colored in yellow) of the timing chain.
    NOTE
    To prevent the exhaust camshaft from spring back, turn it using a wrench and set it at the mark on the chain.



    Click image to see an enlarged view

    Fig. Setting the crankshaft to 20° ATDC-1.5L Engine

  6.  
  7. Install the chain tensioner slipper with the bolt. Tighten to 80 inch lbs. (9 Nm).
  8.  
  9. Install the chain tensioner with the 2 bolts. Tighten to 80 inch lbs. (9 Nm).
  10.  
  11. Remove the bar from the chain tensioner.
  12.  
  13. Install or connect the following:

    Oil pump seal
     
    Oil pump
     
    Water pump
     
    Right-hand engine mount
     
    Camshaft timing oil control valve. Tighten to 66 inch lbs. (8 Nm).
     
    Crankshaft position sensor
     
    Water pump pulley
     
    Crankshaft. Tighten to 95 ft. lbs. (128 Nm).
     
    Cylinder head cover. Tighten to 7 ft. lbs. (10 Nm).
     
    Ignition coil
     
    Engine appearance cover
     
    Alternator
     
    Accessory drive belts
     
    Negative battery cable
     

  14.  
  15. Refill the engine with oil to the correct level.
  16.  
  17. Refill the cooling system to the correct level.
  18.  
  19. Start the engine and check for leaks.
  20.  

2.4L Engine


Click image to see an enlarged view

Fig. Exploded view of the timing chain components-2.4L Engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Support the engine with a suitable jack.
  8.  
  9. Remove or disconnect the following:
    NOTE
    Lift the engine with a suitable jack to gain access to the tensioner mounting bolts.



    Negative battery cable
     
    Hood
     
    Right-hand front wheel
     
    Engine undercover
     
    Front fender apron
     
    Engine appearance cover
     
    Front exhaust pipe
     
    Accessory drive belt
     
    Alternator
     
    Power steering pump and reservoir
     
    Right-hand engine mount
     
    Ignition coil
     
    Cylinder head cover
     
    Accessory drive belt tensioner
     



    Crankshaft position sensor
     
    Oil pan
     

  10.  
  11. Set the No. 1 cylinder to TDC.

    Click image to see an enlarged view

    Fig. Align the timing marks on the camshaft timing gears and Nos. 1 and 2 camshaft bearing caps to ensure the No. 1 cylinder is at TDC compression.

  12.  
  13. Using Special Tool 09213-54015, remove the crankshaft pulley bolt.
  14.  
  15. Remove the crankshaft pulley. Use Special Tool 09950-50013 and the pulley bolt if necessary.
  16.  
  17. Remove or disconnect the following:

    Timing chain tensioner
     
    Front cover
     
    Crankshaft position sensor plate
     
    Timing chain guide
     
    Timing chain tensioner slipper
     
    Upper timing chain
     
    Timing chain vibration damper
     
    Crankshaft sprocket
     

  18.  
  19. Remove the lower timing chain as follows:
    1. Turn the crankshaft by 90° counterclockwise to align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pump.
    2.  
    3. Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock in position, then remove the nut.
    4.  
    5. Remove the bolt, then remove the chain tensioner plate and spring.
    6.  
    7. Remove the oil pump drive gear, oil pump drive shaft gear and lower timing chain.
    8.  

  20.  

To install:

  1. Set the crankshaft key in the left horizontal position. Turn the cutout of the drive shaft to the top.

    Click image to see an enlarged view

    Fig. Set the crankshaft key and drive shaft cutout as shown-2.4L Engine

  2.  
  3. Align the yellow mark links with the timing marks of the each gear as shown in the illustration.

    Click image to see an enlarged view

    Fig. Align the marked links with the timing gear marks-2.4L Engine

  4.  
  5. Install the gears onto the crankshaft and oil pump shaft with the lower chain wrapped.
  6.  
  7. Temporarily tighten the oil pump drive shaft gear with the nut.
  8.  
  9. Insert the damper spring into the adjusting hole, then install the chain tensioner plate with the bolt. Tighten to 9 ft. lbs. (12 Nm).
  10.  
  11. Align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pump.

    Click image to see an enlarged view

    Fig. Insert a bar into the adjusting hole to lock the drive shaft gear in position-2.4L Engine

  12.  
  13. Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock in position, then tighten the nut to 22 ft. lbs. (30 Nm).
  14.  
  15. Turn the crankshaft clockwise by 90° to position the crankshaft key upward.
  16.  
  17. Install the crankshaft sprocket.
  18.  
  19. Turn the camshafts with a wrench on the hexagonal lobe to align the timing marks of the camshaft timing gear with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration.
  20.  
  21. Using the crankshaft pulley bolt, turn the crankshaft to position the key on the crankshaft upward.
  22.  
  23. Install the upper timing chain onto the crankshaft timing gear with the gold or orange mark link aligned with the timing mark on the crankshaft sprocket.

    Click image to see an enlarged view

    Fig. Align the timing marks installing the upper timing chain on the crankshaft sprocket-2.4L Engine

  24.  
  25. Using Special Tool 09309-37010, tap in the crankshaft timing gear.
  26.  
  27. Align the gold or yellow mark links with each timing mark located on the camshaft timing gears, then install the upper timing chain.

    Click image to see an enlarged view

    Fig. Align the timing marks with the camshaft timing gears when installing the upper timing chain-2.4L Engine

  28.  
  29. Install or connect the following:

    Timing chain tensioner slipper. Tighten to 14 ft. lbs. (19 Nm).
     
    Timing chain guide. Tighten to 80 inch lbs. (9 Nm).
     
    Crankshaft position sensor plate
     

  30.  
  31. Remove any old sealant from the front cover.
  32.  
  33. Apply a continuous bead of sealant to the front cover contact surfaces as shown.

    Click image to see an enlarged view

    Fig. Apply sealant to the front cover contact surfaces shown-2.4L Engine

  34.  
  35. Install the front cover. Tighten the bolts as follows:
    1. Bolt A to 80 inch lbs. (9 Nm).
    2.  
    3. Bolts B to 18 ft. lbs. (25 Nm).
    4.  
    5. Bolts C to 41 ft. lbs. (55 Nm).
    6.  
    7. Bolt D to 32 ft. lbs. (43 Nm).
    8.  
    9. Nuts to 8 ft. lbs. (11 Nm).

      Click image to see an enlarged view

      Fig. Front cover bolt identification-2.4L Engine

    10.  

  36.  
  37. Install or connect the following:

    Timing chain tensioner. Tighten to 80 inch lbs. (9 Nm).
     
    Crankshaft pulley. Tighten to 133 ft. lbs. (180 Nm).
     
    Accessory drive belt tensioner. Tighten to 44 ft. lbs. (60 Nm).
     
    Cylinder head cover
     
    Ignition coil
     
    Right-hand engine mount
     
    Power steering pump and reservoir
     
    Alternator
     
    Accessory drive belts
     
    Front exhaust pipe
     
    Engine undercover
     
    Right-hand front fender apron
     
    Front wheel
     
    Negative battery cable
     

  38.  
  39. Refill the engine with oil to the correct level.
  40.  
  41. Refill the cooling system to the correct level.
  42.  
  43. Start the engine and check for leaks.
  44.  

 
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