Toyota Celica, Corolla, ECHO & MR2 1999-05

Timing Chain & Sprockets

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Removal & Installation



1NZ-FE Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Right front wheel
     
    Alternator
     
    Power steering pump
     
    Right engine mount insulator. Use a jack and wood block for support.
     
    With A/C, the bolt holding the liquid tube to the insulator
     
    Ignition coils
     
    Cylinder head cover
     

  6.  
  7. Place No.1 cylinder on TDC compression. Make sure that the timing marks on the camshaft sprockets and valve timing controller assembly are facing UP (12 o-clock). If not, turn the crankshaft 360 degrees to align the marks.
  8.  
  9. Remove or disconnect the following:

    Crankshaft pulley bolt
     
    Pulley and pin
     
    Crankshaft position sensor
     
    Right engine mount bracket
     
    Water pump
     
    Oil control valve
     
    13 bolts, 1 nut and 1 stud bolt. Pry the cover off.
     
    2 O-rings from the block and pan
     
    Chain tensioner
     
    Tensioner slipper
     
    Chain vibration damper
     
    Chain
     

  10.  
  11. Drive the seal from the cover.
  12.  
  13. Pull the chain to its full length and measure the length of any 16 consecutive links. The length should not exceed 4.85 inches (123.2mm).
  14.  
  15. Check the slipper and damper wear. Maximum wear should not exceed 0.039 in. (1mm).
  16.  
  17. The tensioner plunger should move smoothly and lock into place with finger pressure.
  18.  

To install:

  1. Set the crankshaft at 140 degrees ATDC. Set the camshaft sprockets at 20 degrees ATDC; then, reset the crankshaft to 20 degrees ATDC.

    Click image to see an enlarged view

    Fig. Timing chain installation-1NZ-FE engine



    Click image to see an enlarged view

    Fig. Measuring the timing chain-1NZ-FE engine

  2.  
  3. Install or connect the following:
    NOTE
    A new chain will have 3 marked links to align with the 3 sprockets, as shown in the accompanying illustration.



    New seal, driven into place until flush with the cover edge
     
    Vibration damper. Torque the bolts to 80 inch lbs. (9 Nm).
     
    Timing chain
     



    Click image to see an enlarged view

    Fig. Timing cover bolt installation-1NZ-FE engine



    Slipper
     
    Tensioner. Torque the bolts to 80 inch lbs. (9 Nm).
     
    Cover, using a 4-5mm bead of RTV sealer and new O-rings to the block and pan
     

  4.  
  5. Uniformly tighten the bolts in several passes, using the accompanying illustration, to:

    A, C, E and G: 96 inch lbs. (11 Nm)
     
    B, D and F: 18 ft. lbs. (24 Nm)
     

  6.  
  7. Bolt lengths are as follows:

    A: 20mm
     
    B: 30mm
     
    C: 35mm
     
    D: 20mm
     
    E: 35mm
     

  8.  
  9. Install or connect the following:

    Right engine mount bracket. Coat all but the end 2 threads of the bolt with RTV sealer. Torque the bolt to 41 ft. lbs. (55 Nm).
     
    Crankshaft position sensor. Torque bolt A to 66 inch lbs. (7.5 Nm); bolts B to 96 inch lbs. (11 Nm).
     
    Oil control valve. Torque: 71 inch lbs. (8 Nm).
     
    Crankshaft pulley and pin. Torque the bolt to 94 ft. lbs. (128 Nm).
     
    Cylinder head cover with RTV gasket material at the 2 locations shown. Uniformly tighten the bolts and nuts, in several passes, to 84 inch lbs. (10 Nm).
     
    PCV hoses
     
    Ignition coils
     
    Right engine mount insulator. Torque the bolts and nuts to 35 ft. lbs. (47 Nm).
     
    Power steering pump
     
    Alternator
     
    Right under cover
     
    Wheel
     
    Negative battery cable
     

  10.  
  11. Fill the cooling system to the proper level.
  12.  
  13. Start the vehicle, check for leaks and repair if necessary.
  14.  

1ZZ-FE Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Right engine cover
     
    Accessory drive belt and generator
     
    Power steering pump, without disconnecting the hoses
     
    Right engine mount
     
    Cylinder head cover
     
    Turn the crankshaft so the No. 1 piston is at TDC on the compression stroke
     
    Crankshaft pulley
     
    Crankshaft position sensor from the timing chain cover
     
    Accessory drive belt tensioner
     
    Right engine mounting bracket
     
    Chain tensioner
     
    Water pump
     
    Timing chain cover
     
    Crankshaft angle sensor plate
     
    Timing chain tensioner slipper
     
    Timing chain and crankshaft timing sprocket
     

  6.  

To install:

  1. Install or connect the following:

    Crankshaft sprocket with timing chain. Be sure to align the No. 1 mark link with the mark on the sprocket
     
    Timing chain on the camshaft sprockets. Align the Nos. 53 and 67 mark links with the marks on the camshaft sprockets

    Click image to see an enlarged view

    Fig. Align the No. 1 mark link with the mark on the crankshaft sprocket-1.8L (1ZZ-FE) engine



    Click image to see an enlarged view

    Fig. Align mark links Nos. 53 and 67 with the marks on the camshaft sprockets as shown-1.8L (1ZZ-FE) engine

     
    Chain tensioner slipper. Bolt: 14 ft. lbs. (18.5 Nm).
     
    Crankshaft angle sensor plate
     
    New seal in the front cover
     
    Silicone sealant to the timing chain cover as illustrated
     
    Timing chain cover
     

  2.  
  3. Water pump. Tighten the bolts marked -C- to 80 inch lbs. (9 Nm) and tighten the remaining bolts to 14 ft. lbs. (18.5 Nm). Be sure to install the bolts in their original locations. Bolt lengths:
    1. A: 1.77 in. (45mm)
    2.  
    3. B: 1.38 in. (35mm)
    4.  
    5. C: 1.18 in. (30mm)
    6.  
    7. D: 0.98 in. (25mm)

      Click image to see an enlarged view

      Fig. Timing chain cover bolt identification-1.8L (1ZZ-FE) engine

    8.  

  4.  
  5. Install or connect the following:

    Right engine mounting bracket. Bolts, with sealant applied: 35 ft. lbs. (47 Nm).
     
    Drive belt tensioner. Bolt: 51 ft. lbs. (69 Nm). Nut: 21 ft. lbs. (29 Nm).
     
    Crankshaft position sensor. Tighten to 80 inch lbs. (9 Nm).
     
    Crankshaft pulley. Bolt: 102 ft. lbs. (138 Nm).
     

  6.  
  7. Release the ratchet pawl and compress the chain tensioner. Place the hook on the pin to keep the tensioner compressed.

    Click image to see an enlarged view

    Fig. Compress the timing chain tensioner and place the hook on the pin-1.8L (1ZZ-FE) engine

  8.  
  9. Install the tensioner, using a new O-ring. Torque the bolts to 80 inch lbs. (9 Nm).
  10.  
  11. Turn the crankshaft counterclockwise and remove the hook from the pin. Turn the crankshaft clockwise and be sure the slipper is pushed by the plunger.
  12.  
  13. Check the valve timing by turning the crankshaft clockwise until the mark of the pulley is aligned with the mark on the timing chain cover. The marks on the camshaft sprockets should be facing each other as shown.
  14.  
  15. Install or connect the following:

    Silicone sealant to the 2 areas where the timing chain cover meets the cylinder head.
     
    Cylinder head cover. Bolts with washers in the sequence shown: 80 inch lbs. (9 Nm). Bolts without washers: 96 inch lbs. (11 Nm).
     
    Right engine mount. Bolts: Marked A : 47 ft. lbs. (64 Nm). Marked B : 19 ft. lbs. (26 Nm). Nut: 38 ft. lbs. (52 Nm).
     
    Power steering pump
     
    Alternator and drive belt
     
    Right engine undercover
     
    Negative battery cable
     
    Washer tank
     

  16.  
  17. Fill the cooling system to the proper level.
  18.  
  19. Start the vehicle, check for leaks and repair if necessary.
  20.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Right engine cover
     
    Accessory drive belt and generator
     
    Power steering pump, without disconnecting the hoses.
     
    Right engine mount
     
    Cylinder head cover
     
    Turn the crankshaft so the No. 1 piston is at TDC on the compression stroke.
     
    Crankshaft pulley
     
    Crankshaft position sensor from the timing chain cover.
     
    Accessory drive belt tensioner.
     
    Right engine mounting bracket
     
    Chain tensioner
     
    Water pump
     
    Timing chain cover
     
    Crankshaft angle sensor plate
     
    Timing chain tensioner slipper
     
    Timing chain and crankshaft timing sprocket.
     
    Timing chain vibration damper
     
    Valve timing control assembly and camshaft timing sprocket
     

  6.  
  7. Drive the seal from the cover.
  8.  
  9. Pull the chain to its full length and measure the length of any 16 consecutive links. The length should not exceed 4.827 inches (122.6mm).
  10.  
  11. Check the slipper and damper wear. Maximum wear should not exceed 0.039 in. (1mm).
  12.  
  13. The tensioner plunger should move smoothly and lock into place with finger pressure.
  14.  

To install:

  1. Apply engine oil from the tip of the intake camshaft, back to 16mm.
  2.  
  3. Align the timing mark on the valve timing controller with the knock pin and gently push the valve timing controller onto the camshaft.
  4.  
  5. Set the No.1 piston to TDC compression. The key on the crankshaft should be at 12 o-clock.
  6.  
  7. Install or connect the following:

    Sprockets. Torque the bolt to 33 ft. lbs. (45 Nm). Turn the camshafts to align the point marks on the sprockets.
     
    Chain damper. Bolts: 96 inch lbs. (11 Nm).
     
    Timing chain and crankshaft sprocket. Be sure to align the yellow chain link with the mark on the crankshaft sprocket.
     
    Timing chain on the camshaft sprockets. Align the yellow links with the marks on the camshaft sprockets.
     
    Chain tensioner slipper. Bolt: 14 ft. lbs. (18.5 Nm).
     
    Crankshaft angle sensor plate with the F mark forward
     
    New seal in the front cover
     
    Silicone sealant to the timing chain cover as illustrated
     
    Timing chain cover
     

  8.  
  9. Water pump. Tighten the 10mm bolts marked -C- to 80 inch lbs. (9 Nm), those marked -A- to 10 ft. lbs. (13 Nm), and the remaining 10mm bolts to 96 inch lbs. (11 Nm). Tighten the 12mm bolts to 14 ft. lbs. (18.5 Nm). Be sure to install the bolts in their original locations. Bolt lengths:
    1. A: 1.77 in. (45mm).
    2.  
    3. B: 1.38 in. (35mm).
    4.  
    5. C: 1.18 in. (30mm).
    6.  
    7. D: 0.98 in. (25mm).
    8.  

  10.  
  11. With a Torx wrench, tighten the stud bolt to 82 inch lbs. (9.3 Nm).
  12.  
  13. Install or connect the following:

    Right engine mounting bracket. Bolts, with sealant applied: 35 ft. lbs. (47 Nm).
     
    Drive belt tensioner. Bolt: 51 ft. lbs. (69 Nm). Nut: 21 ft. lbs. (29 Nm).
     
    Crankshaft position sensor. Tighten to 80 inch lbs. (9 Nm).
     
    Crankshaft pulley. Bolt: 102 ft. lbs. (138 Nm).
     

  14.  
  15. Release the ratchet pawl and compress the chain tensioner. Place the hook on the pin to keep the tensioner compressed.
  16.  
  17. Install the tensioner, using a new O-ring. Torque the bolts to 80 inch lbs. (9 Nm).
  18.  
  19. Turn the crankshaft counterclockwise and remove the hook from the pin. Turn the crankshaft clockwise and be sure the slipper is pushed by the plunger.
  20.  
  21. Check the valve timing by turning the crankshaft clockwise until the mark of the pulley is aligned with the mark on the timing chain cover. The marks on the camshaft sprockets should be facing each other as shown.
  22.  
  23. Install or connect the following:

    Silicone sealant to the 2 areas where the timing chain cover meets the cylinder head.
     
    Cylinder head cover. Bolts with washers in the sequence shown: 80 inch lbs. (9 Nm). Bolts without washers: 96 inch lbs. (11 Nm).
     
    Right engine mount. Bolts and nuts: 38 ft. lbs. (52 Nm).
     
    Power steering pump
     
    Alternator and drive belt
     
    Right engine undercover
     
    Negative battery cable
     
    Washer tank
     

  24.  
  25. Fill the cooling system to the proper level.
  26.  
  27. Start the vehicle, check for leaks and repair if necessary.

    Click image to see an enlarged view

    Fig. Timing chain link marks-1ZZ-FE and 2ZZ-GE engines

  28.  

2zz-Ge And 2zz-FE Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Right engine cover
     
    Accessory drive belt and generator
     
    Power steering pump, without disconnecting the hoses.
     
    Right engine mount
     
    Cylinder head cover
     
    Turn the crankshaft so the No. 1 piston is at TDC on the compression stroke.
     
    Crankshaft pulley
     
    Crankshaft position sensor from the timing chain cover.
     
    Accessory drive belt tensioner.
     
    Right engine mounting bracket
     
    Chain tensioner
     
    Water pump
     
    Timing chain cover
     
    Crankshaft angle sensor plate
     
    Timing chain tensioner slipper
     
    Timing chain and crankshaft timing sprocket.
     
    Timing chain vibration damper
     
    Valve timing control assembly and camshaft timing sprocket
     

  6.  
  7. Drive the seal from the cover.
  8.  
  9. Pull the chain to its full length and measure the length of any 16 consecutive links. The length should not exceed 4.827 inches (122.6mm).
  10.  
  11. Check the slipper and damper wear. Maximum wear should not exceed 0.039 in. (1mm).
  12.  
  13. The tensioner plunger should move smoothly and lock into place with finger pressure.

    Click image to see an enlarged view

    Fig. Timing mark identification at TDC compression-2ZZ-GE engine

  14.  

To install:

  1. Apply engine oil from the tip of the intake camshaft, back to 16mm.
  2.  
  3. Align the timing mark on the valve timing controller with the knock pin and gently push the valve timing controller onto the camshaft.
  4.  
  5. Set the No.1 piston to TDC compression. The key on the crankshaft should be at 12 o-clock.
  6.  
  7. Install or connect the following:

    Sprockets. Torque the bolt to 33 ft. lbs. (45 Nm). Turn the camshafts to align the point marks on the sprockets.
     
    Chain damper. Bolts: 96 inch lbs. (11 Nm).
     
    Timing chain and crankshaft sprocket. Be sure to align the yellow chain link with the mark on the crankshaft sprocket.
     
    Timing chain on the camshaft sprockets. Align the yellow links with the marks on the camshaft sprockets.
     
    Chain tensioner slipper. Bolt: 14 ft. lbs. (18.5 Nm).
     
    Crankshaft angle sensor plate with the F mark forward
     
    New seal in the front cover
     
    Silicone sealant to the timing chain cover as illustrated
     
    Timing chain cover
     

  8.  
  9. Install the water pump. Tighten the 10mm bolts marked -C- to 80 inch lbs. (9 Nm), those marked -A- to 10 ft. lbs. (13 Nm), and the remaining 10mm bolts to 96 inch lbs. (11 Nm). Tighten the 12mm bolts to 14 ft. lbs. (18.5 Nm). Be sure to install the bolts in their original locations. Bolt lengths:
    1. A: 1.77 in. (45mm).
    2.  
    3. B: 1.38 in. (35mm).
    4.  
    5. C: 1.18 in. (30mm).
    6.  
    7. D: 0.98 in. (25mm).
    8.  

  10.  
  11. With a Torx wrench, tighten the stud bolt to 82 inch lbs. (9.3 Nm).
  12.  
  13. Install or connect the following:

    Right engine mounting bracket. Bolts, with sealant applied: 35 ft. lbs. (47 Nm).
     
    Drive belt tensioner. Bolt: 51 ft. lbs. (69 Nm). Nut: 21 ft. lbs. (29 Nm).
     
    Crankshaft position sensor. Tighten to 80 inch lbs. (9 Nm).
     
    Crankshaft pulley. Bolt: 102 ft. lbs. (138 Nm).
     

  14.  
  15. Release the ratchet pawl and compress the chain tensioner. Place the hook on the pin to keep the tensioner compressed.
  16.  
  17. Install the tensioner, using a new O-ring. Torque the bolts to 80 inch lbs. (9 Nm).
  18.  
  19. Turn the crankshaft counterclockwise and remove the hook from the pin. Turn the crankshaft clockwise and be sure the slipper is pushed by the plunger.
  20.  
  21. Check the valve timing by turning the crankshaft clockwise until the mark of the pulley is aligned with the mark on the timing chain cover. The marks on the camshaft sprockets should be facing each other as shown.
  22.  
  23. Install or connect the following:

    Silicone sealant to the 2 areas where the timing chain cover meets the cylinder head.
     
    Cylinder head cover. Bolts with washers in the sequence shown: 80 inch lbs. (9 Nm). Bolts without washers: 96 inch lbs. (11 Nm).
     
    Right engine mount. Bolts and nuts: 38 ft. lbs. (52 Nm).
     
    Power steering pump
     
    Alternator and drive belt
     
    Right engine undercover
     
    Negative battery cable
     
    Washer tank
     

  24.  
  25. Fill the cooling system to the proper level.
  26.  
  27. Start the vehicle, check for leaks and repair if necessary.
  28.  

 
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