Toyota Avalon, Camry, Camry Solara 2001-06

Timing Chain & Sprockets

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Removal & Installation



2az-FE Engine


Click image to see an enlarged view

Fig. Exploded view of the timing chain and front cover components-2.4L (2AZ-FE) engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Right-side front wheel
     
    Engine under covers
     
    Right-side fender apron seal
     
    Front exhaust pipe
     
    Engine moving control rod and bracket
     
    Right-side engine mounting stay and bracket
     
    Accessory drive belt
     
    Engine appearance cover
     
    Engine wire
     
    Alternator
     
    Power steering pump, leave the hoses connected
     
    Ignition coils
     
    Ventilation hoses
     
    Cylinder head cover
     

  6.  
  7. Turn the crankshaft pulley to set the No. 1 cylinder to TDC compression. Align the groove on the pulley with the timing mark -0- on the front cover.
  8.  
  9. Remove the crankshaft pulley as follows:
    1. TMC made: Use Special Tool 09213-54015 to hold the pulley to loosen the bolt. Use Special Tool 09950-50013 to remove the bolt and pulley.
    2.  
    3. TMMK made: Use Special Tool 09960-10010 to hold the pulley to remove the bolt. Use Special Tool 09950-40011 to remove the crankshaft pulley

      Click image to see an enlarged view

      Fig. Removing the crankshaft pulley-TMC-2.4L (2AZ-FE) engine



      Click image to see an enlarged view

      Fig. Removing the crankshaft pulley-TMMK-2.4L (2AZ-FE) engine

    4.  

  10.  
  11. Remove or disconnect the following:

    Crankshaft position sensor
     
    Lower oil pan
     
    No. 1 chain tensioner
     
    Accessory drive belt tensioner
     

  12.  
  13. Support the engine with a suitable engine lifting device.
  14.  
  15. Remove or disconnect the following:

    Engine mounting insulators
     
    Right-side engine mounting bracket
     
    Stud bolt for the accessory drive belt tensioner from the block
     
    Front cover mounting bolts and nuts
     
    Front cover
     
    Crankshaft position sensor plate
     
    Timing chain tensioner slipper
     
    Timing chain vibration damper
     
    Timing chain
     
    Crankshaft timing sprocket
     

  16.  
  17. Turn the crankshaft counterclockwise by 90°, and align an adjusting hole of the oil pump driven sprocket with the groove of the oil pump.

    Click image to see an enlarged view

    Fig. Align the adjusting hole of the oil pump drive sprocket with the oil pump groove-2.4L (2AZ-FE) engine



    Click image to see an enlarged view

    Fig. Insert a bar to lock the sprocket in position-2.4L (2AZ-FE) engine

  18.  
  19. Put a bar in the adjusting hole of the oil pump driven sprocket to temporarily lock the sprocket in position. Remove the nut.
  20.  
  21. Remove the bolt, chain tensioner and spring.
  22.  
  23. Remove the chain tensioner, oil pump sprocket and No. 2 timing chain.
  24.  

To install:

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

    Click image to see an enlarged view

    Fig. Align the crankshaft key and drive shaft cutout as shown for installation-2.4L (2AZ-FE) engine

  2.  
  3. Align the yellow colored links with the timing marks of the sprocket as shown in the illustration.
  4.  
  5. Insert the sprockets with chain to the crankshaft and oil pump shaft.
  6.  
  7. Temporarily tighten the oil pump driven sprocket with the nut.
  8.  
  9. Insert the damper spring into the adjusting hole, and install the chain tensioner plate with the nut. Tighten to 9 ft. lbs. (12 Nm).
  10.  
  11. Align the adjusting hole of the oil pump driven sprocket with the groove of the oil pump.
  12.  
  13. Put a bar in the adjusting hole of the oil pump driven sprocket to temporarily lock the sprocket in position. Tighten the nut to 22 ft. lbs. (30 Nm).
  14.  
  15. Rotate the crankshaft counterclockwise by 90°, and align the crankshaft key to the top.
  16.  
  17. Install the timing chain vibration damper. Tighten to 80 inch lbs. (9 Nm).
  18.  
  19. Align the timing marks of the camshaft timing sprockets and bearing caps.
  20.  
  21. Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward.
  22.  
  23. Align the gold or orange colored link with the timing mark of the crankshaft timing sprocket.
  24.  
  25. Using Special Tool 09309-37010, tap in the sprocket.
  26.  
  27. Align the gold or yellow colored links with the timing marks of the camshaft timing gear and camshaft timing sprocket. Install the chain.

    Click image to see an enlarged view

    Fig. Align the marks of the sprockets and bearing caps to set the No. 1 cylinder at TDC-2.4L (2AZ-FE) engine



    Click image to see an enlarged view

    Fig. Set the crankshaft set key facing upward-2.4L (2AZ-FE) engine



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    Fig. Align the marked link of the timing chain with crankshaft sprocket timing mark-2.4L (2AZ-FE) engine



    Click image to see an enlarged view

    Fig. Tap the crankshaft sprocket in with Special Tool 09309-37010-2.4L (2AZ-FE) engine



    Click image to see an enlarged view

    Fig. Align the marked links of the timing chain with the camshaft sprockets during installation-2.4L (2AZ-FE) engine

  28.  
  29. Install the timing chain tensioner slipper. Tighten to 14 ft. lbs. (19 Nm).
  30.  
  31. Install the crankshaft position sensor plate. The -F- mark faces forward.
  32.  
  33. Clean any old gasket material from the mating surfaces of the front cover, cylinder head and block.
  34.  
  35. Apply a continuous bead of sealant to the front cover mating surface either 0.10 in. (2.5 mm) or 0.12-0.16 (3-4 mm) in diameter as indicated in the illustration.

    Click image to see an enlarged view

    Fig. Apply sealant to the front cover mating surface as shown-2.4L (2AZ-FE) engine

  36.  
  37. Install the front cover and tighten as follows:
    1. Bolt A and nuts: 80 inch lbs. (9 Nm).
    2.  
    3. Bolts B: 15 ft. lbs. (21 Nm).
    4.  
    5. Bolts C: 32 ft. lbs. (43 Nm).

      Click image to see an enlarged view

      Fig. Bolt and nut identification for the front cover-2.4L (2AZ-FE) engine

    6.  

  38.  
  39. Install or connect the following:

    Stud bolt for the accessory drive belt. Tighten to 7 ft. lbs. (10 Nm).
     
    Accessory drive belt tensioner. Tighten to 44 ft. lbs. (60 Nm).
     
    Right-hand engine mounting bracket. Tighten to 40 ft. lbs. (54 Nm).
     
    Engine mounting insulator. Tighten top bolt to 70 ft. lbs. (95 Nm) and bottom bolts to 64 ft. lbs. (87 Nm).
     
    Lower oil pan. Tighten bolts to 80 inch lbs. (9 Nm).
     
    Timing chain tensioner
     
    Crankshaft position sensor. Tighten to 80 inch lbs. (9 Nm).
     

  40.  
  41. Align the crankshaft pulley key set with the key groove of the pulley, and side on the pulley. Using the Special Tool previous used to remove, tighten the crankshaft pulley bolt to 125 ft. lbs. (170 Nm).
  42.  
  43. Turn the crankshaft counterclockwise and disconnect the plunger knock pin from the hook.
  44.  
  45. Turn the crankshaft clockwise and check that the slipper is pushed by the plunger.
  46.  
  47. The remainder of the installation is the reverse order of removal.
  48.  
  49. Refill the engine with oil to the correct level.
  50.  
  51. Start the engine and check for leaks.
  52.  

2gr-FE Engine


Click image to see an enlarged view

Fig. Exploded view of the timing chain and front cover components-3.5L (2GR-FE) engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the engine/transaxle assembly from the vehicle.
  4.  
  5. Remove the transaxle.
  6.  
  7. Remove the oil dipstick tube.
  8.  
  9. Remove the driveplate.
  10.  
  11. Install the engine to a suitable engine stand.
  12.  
  13. Remove or disconnect the following:

    Idler pulley
     
    Right-side engine mounting bracket
     
    Accessory drive belt tensioner
     
    Water pump pulley
     
    No. 2 timing gear cover
     
    Engine mounting stay and bracket
     
    Water inlet housing
     

  14.  
  15. Using Special Tool 09213-70011, hold the crankshaft pulley and loosen the pulley bolt.
  16.  
  17. Using the pulley bolt and Special Tool 09950-50013, remove the crankshaft pulley.

    Click image to see an enlarged view

    Fig. Loosen the crankshaft pulley bolt with Special Tool 09213-70011-3.5L (2GR-FE) engine



    Click image to see an enlarged view

    Fig. Remove the crankshaft pulley with Special Tool 09950-50013-3.5L (2GR-FE) engine

  18.  
  19. Remove or disconnect the following:

    Upper and lower oil pans
     
    O-rings from the oil pump
     
    Air intake surge tank
     
    Ignition coils
     
    Oil pipes
     
    Cylinder head cover
     

  20.  
  21. Remove the mounting bolts from the front cover.
  22.  
  23. Using a suitable pry tool with the tip covered with protective tape, pry the front cover in the specified locations to remove.

    Click image to see an enlarged view

    Fig. Pry the front cover at the locations shown in the illustration-3.5L (2GR-FE) engine

  24.  
  25. Pry the front crankshaft seal from the front cover.

    Click image to see an enlarged view

    Fig. Removing the seal from the front cover-3.5L (2GR-FE) engine

  26.  
  27. Temporarily tighten the pulley set bolt.
  28.  
  29. Set the timing mark on the crank angle sensor plate to the right-hand block bore center line to put the No. 1 cylinder at TDC.
  30.  
  31. 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 one complete revolution (360°) and align the timing marks as shown.
  32.  
  33. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
  34.  
  35. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the stopper plate-s hole.
  36.  
  37. Remove the chain tensioner.
  38.  
  39. Remove the chain tensioner slipper.

    Click image to see an enlarged view

    Fig. Align the timing mark on the sensor plate and block to set the No. 1 cylinder at TDC-3.5L (2GR-FE) engine



    Click image to see an enlarged view

    Fig. Ensure the timing marks of the camshaft timing gears are aligned with the bearing cap timing marks-3.5L (2GR-FE) engine



    Click image to see an enlarged view

    Fig. Procedure to remove the timing chain tensioner-3.5L (2GR-FE) engine

  40.  
  41. Turn the crankshaft 10° counterclockwise to loosen the chain off the crankshaft timing gear.
  42.  
  43. Remove the timing chain from the crank timing gear and place it on the crankshaft.
  44.  
  45. Turn the camshaft timing gear on the right-side bank clockwise (approximately 60°). Be sure to loosen the chain between the center banks.
  46.  
  47. Remove the timing chain.

    Click image to see an enlarged view

    Fig. Turn the crankshaft counterclockwise to loosen the timing chain-3.5L (2GR-FE) engine

  48.  

To install:

  1. Align the orange marked links and timing mark as shown in the illustration and install the timing chain.
  2.  
  3. Turn the camshaft timing gear on the right-side bank counterclockwise to tighten the chain between banks.
  4.  
  5. Align the yellow marked link and timing mark as shown in the illustration and install the chain onto the crankshaft timing gear.
  6.  
  7. Temporarily tighten the crankshaft pulley set bolt.

    Click image to see an enlarged view

    Fig. Align the timing chain marked links with the camshaft timing gear marks to install-3.5L (2GR-FE) engine



    Click image to see an enlarged view

    Fig. Align the timing chain marked link with the crankshaft gear to install-3.5L (2GR-FE) engine

  8.  
  9. Install the chain tensioner slipper.
  10.  
  11. Install the chain tensioner as follows:
    1. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
    2.  
    3. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.
    4.  
    5. Install the chain tensioner and tighten the bolts to 7 ft. lbs. (10 Nm).
    6.  
    7. Remove the lock pin of chain tensioner.
    8.  

  12.  
  13. Check that each timing mark is aligned with the crankshaft at TDC compression.
  14.  
  15. Remove the pulley set bolt.
  16.  
  17. Using Special Tool 09316-60011 or equivalent seal driver, tap in a new front oil seal into the front cover until its surface is flush with the front cover case edge. Apply multi-purpose grease to the oil seal lip.

    Click image to see an enlarged view

    Fig. Tap a new oil seal into place in the front cover-3.5L (2GR-FE) engine

  18.  
  19. Install the front cover as follows:
    1. Apply a continuous bead of sealant 0.118 in. (3 mm) in diameter to the engine as shown in the illustration.
    2.  


      Click image to see an enlarged view

      Fig. Apply sealant to the engine block as shown when installing the front cover-3.5L (2GR-FE) engine

    3. Apply sealant to the front cover as shown in the illustration.

      Click image to see an enlarged view

      Fig. Apply sealant to the front cover as specified by the illustration-3.5L (2GR-FE) engine

    4.  
    5. Install a new oil pump gasket.
    6.  
    7. Align the oil pump-s drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.

      Click image to see an enlarged view

      Fig. Correct orientation of the oil pump rotor and crankshaft during installation of the front cover-3.5L (2GR-FE) engine

    8.  
    9. Install the front cover and loosely install all of the mounting bolts and nuts. Bolts A are 1.57 in. (40 mm); Bolts B are 2.17 in. (55 mm); Bolts C are 0.98 in. (25 mm).
    10.  
    11. Fully tighten the bolts in sequence as follows:

      Areas 1 and 2: 15 ft. lbs. (21 Nm)
       
      Area 3: 15 ft. lbs. (21 Nm)
       
      Area 4: 32 ft. lbs. (43 Nm) for Bolt A; 15 ft. lbs. (21 Nm) for all other bolts

      Click image to see an enlarged view

      Fig. Bolt identification and torque sequence for the front cover-3.5L (2GR-FE) engine

       

    12.  

  20.  
  21. The remainder of the installation is the reverse order of removal.
  22.  
  23. Start the engine and check for leaks.
  24.  

 
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