Vibe 2003-2005

Timing Chain Cover, Chain, Sprockets, & Seal

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Removal & Installation



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

    Right side engine under cover
     
    Right front wheel and tire
     
    Cylinder head cover
     
    Wire harness clamp and suction hose assembly, 2ZZ-GE engine
     
    Drive belt
     

  6.  
  7. Separate the vane pipe assembly, but do not disconnect the hose, 1ZZ-FE engine.

    Alternator bracket, 2ZZ-GE
     
    Alternator
     



    Power steering pump reservoir and position it aside, 1ZZ-FE engine
     

  8.  
  9. Place a jack with a wooden block under the vehicle for support, then remove the 4 bolts and 2 nuts and remove the right side engine mount.

    Click image to see an enlarged view

    Fig. With the engine supported, remove the right side engine mount-1ZZ-FE engine shown, 2ZZ-GE similar

  10.  
  11. Remove the engine wire as follows, on 1ZZ-FE engines:
    1. Remove the 5 clamps from the brackets.
    2.  
    3. Detach the connectors.
    4.  
    5. Remove the ignition coil connectors.
    6.  
    7. Bolt and nut holding the engine wire.
    8.  

  12.  
  13. Remove the engine wire as follows, on 2ZZ-GE engines:
    1. Detach the ignition coil, oil control valve and Crankshaft Position Sensor (CKP) sensor electrical connectors.
    2.  
    3. Bolt and nut for the engine ground, then position the engine wire aside
    4.  

  14.  
  15. Remove or disconnect the following:

    Ignition coil assembly
     
    Positive Crankcase Ventilation (PCV) hoses from the cylinder head cover, if necessary
     
    Cylinder head (valve) cover sub-assembly
     

  16.  
  17. Set the No. 1 cylinder to Top Dead Center (TDC) of the compressor stroke as follows:
    1. Turn the crankshaft pulley, and align its groove with the -0- timing mark of the timing chain cover.
    2.  
    3. Make sure the point marks of the camshaft timing sprockets and VVT timing sprockets are in a straight line as shown. If not, turn the crankshaft 1 complete revolution (360°) and align the marks.
      NOTE
      In case you turn the camshafts with the timing chain removed, turn the crankshaft 1 / 4 turn for the valve to avoid contact with the pistons.



      Click image to see an enlarged view

      Fig. Proper timing mark alignment for TDC



      Crankshaft pulley, using SST 09960-10010
       
      Belt tensioner
       
      Water pump pulley, if equipped, and pump
       
      Transverse engine mounting bracket
       
      Crankshaft Position (CKP) sensor
       
      No. 1 chain tensioner assembly, making sure not to revolve the crankshaft without the tensioner
       
      Timing chain cover. The cover is retained with 11 bolts and nuts and a Torx® stud bolt. Pry the cover between the cylinder head and block to remove it.

      Click image to see an enlarged view

      Fig. Timing chain cover mounting-1ZZ-FE engine shown, 2ZZ-GE similar

       
      Timing gear cover oil seal
       
      CKP sensor plate No. 1
       
      Timing chain tensioner slipper
       



      Timing chain sub-assembly. Remove the chain with the crankshaft gear, using screwdrivers as shown.

      Click image to see an enlarged view

      Fig. Remove the timing chain with the crankshaft gear

       

    4.  

  18.  

To install:

  1. Set the No. 1 cylinder to TDC of the compression stroke:
    1. Turn the hexagonal wrench head part of the camshafts, and align the point marks of the cam sprockets.

      Click image to see an enlarged view

      Fig. Proper alignment of the camshaft sprockets-1ZZ-FE engine



      Click image to see an enlarged view

      Fig. Proper alignment of the camshaft sprockets-2ZZ-GE engine

    2.  
    3. Using the crankshaft pulley bolt, turn the crankshaft and position the crankshaft set key upward.
    4.  

  2.  
  3. Install or connect the following:
    NOTE
    When installing the tensioner, make sure to set the hook again if the hook releases the plunger.



    Timing chain on the crank sprocket with the yellow link aligned with the mark on the crank sprocket. There are 3 yellow links on the timing chain.

    Click image to see an enlarged view

    Fig. Make sure the yellow link is aligned with the crankshaft sprocket timing mark-1ZZ-FE and 2ZZ-GE engines

     
    Crankshaft sprocket, using SST 09223-22010
     
    Timing chain on the camshaft sprockets with the yellow links aligned with the marks on the cam sprockets

    Click image to see an enlarged view

    Fig. The yellow links of the timing chain must align with the camshaft sprocket timing marks-1ZZ-FE and 2ZZ-GE engines

     
    Timing chain tensioner slipper and tighten the bolt to 14 ft. lbs. (19 Nm)
     
    Crankshaft position sensor plate, with the -F- mark facing forward
     
    Timing gear cover oil seal
     
    Timing cover. For 1ZZ-FE engine, tighten the -A- bolts to 10 ft. lbs. (13 Nm), the -B- bolts to 14 ft. lbs. (19 Nm) and the stud bolt to 84 inch lbs. (9.5 Nm), using a Torx® wrench. For 2ZZ-GE engines, tighten the M8 bolts to 15 ft. lbs. (21 m), the M6 bolts to 8 ft. lbs. (11 Nm) and the stud bolt to 84 inch lbs. (9.5 Nm).
     



    Timing chain tensioner. Torque the nuts to 80 inch lbs. (9 Nm).

    Click image to see an enlarged view

    Fig. Timing chain tensioner-1ZZ-FE engine

     
    CKP sensor and tighten the bolts to 80 inch lbs. (9 Nm)
     
    Transverse engine mounting bracket. Tighten the bolts to 35 ft. lbs. (47 Nm).
     
    Water pump and pulley
     
    Drive belt tensioner. Tighten the nut to 21 ft. lbs. (29 Nm) and the bolt to 51 ft. lbs. (69 Nm) on 1ZZ-FE engines or to 74 ft. lbs. (100 Nm) on 2ZZ-GE engines.
     

  4.  
  5. Install the crankshaft pulley, as follows:
    1. Align the pulley set key with the key groove of the pulley and slide on the pulley.
    2.  
    3. Use SST 09960-11010 to install the bolt and tighten to 102 ft. lbs. (138 Nm) for 1ZZ-FE engine or to 87 ft. lbs. (118 Nm) on 2ZZ-GE engines.
    4.  
    5. Turn the crankshaft counterclockwise and disconnect the plunger knock pin from the hook.
    6.  
    7. Turn the crankshaft clockwise and check that the slipper is pushed by the plunger. 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 plunder springs out.

      Cylinder head sub-assembly cover. Install seal packing into the locations shown and install within 3 minutes. Tighten the -A- bolts to 8 ft. lbs. (11 Nm) and the -B- bolts to 80 inch lbs. (9 Nm) for 1ZZ-FE engines. For 2ZZ-GE engines, tighten the bolts to 7 ft. lbs. (10 Nm).

      Click image to see an enlarged view

      Fig. Seal packing installation locations



      Click image to see an enlarged view

      Fig. Cylinder head (valve) cover bolt locations-1ZZ-FE engine

       
      Ignition coil assembly. Torque the bolts to 80 inch lbs. (9 Nm).
       
      Engine wire and tighten to 80 inch lbs. (9 Nm)
       
      Right side engine mount. Tighten to 38 ft. lbs. (52 Nm).
       
      Alternator bracket, 2ZZ-GE engine
       
      Alternator
       
      Vane pump, 1ZZ-FE
       
      Main cylinder head cover and tighten to 62 inch lbs. (7 Nm)
       
      Right front wheel and tire. Tighten the lug nuts to 76 ft. lbs. (103 Nm).
       

    8.  

  6.  
  7. Fill the cooling system to the proper level.
  8.  
  9. Start the vehicle, check for leaks and repair if necessary.
  10.  

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

    Right side engine under cover
     
    Right front wheel and tire
     
    Cylinder head cover
     
    Wire harness clamp and suction hose assembly, 2ZZ-GE engine
     
    Drive belt
     

  6.  
  7. Separate the vane pipe assembly, but do not disconnect the hose, 1ZZ-FE engine.

    Alternator bracket, 2ZZ-GE
     
    Alternator
     



    Power steering pump reservoir and position it aside, 1ZZ-FE engine
     

  8.  
  9. Place a jack with a wooden block under the vehicle for support, then remove the 4 bolts and 2 nuts and remove the right side engine mount.

    Click image to see an enlarged view

    Fig. With the engine supported, remove the right side engine mount-1ZZ-FE engine shown, 2ZZ-GE similar

  10.  
  11. Remove the engine wire as follows, on 1ZZ-FE engines:
    1. Remove the 5 clamps from the brackets.
    2.  
    3. Detach the connectors.
    4.  
    5. Remove the ignition coil connectors.
    6.  
    7. Bolt and nut holding the engine wire.
    8.  

  12.  
  13. Remove the engine wire as follows, on 2ZZ-GE engines:
    1. Detach the ignition coil, oil control valve and Crankshaft Position Sensor (CKP) sensor electrical connectors.
    2.  
    3. Bolt and nut for the engine ground, then position the engine wire aside
    4.  

  14.  
  15. Remove or disconnect the following:

    Ignition coil assembly
     
    Positive Crankcase Ventilation (PCV) hoses from the cylinder head cover, if necessary
     
    Cylinder head (valve) cover sub-assembly
     

  16.  
  17. Set the No. 1 cylinder to Top Dead Center (TDC) of the compressor stroke as follows:
    1. Turn the crankshaft pulley, and align its groove with the -0- timing mark of the timing chain cover.
    2.  
    3. Make sure the point marks of the camshaft timing sprockets and VVT timing sprockets are in a straight line as shown. If not, turn the crankshaft 1 complete revolution (360°) and align the marks.
      NOTE
      In case you turn the camshafts with the timing chain removed, turn the crankshaft 1 / 4 turn for the valve to avoid contact with the pistons.



      Click image to see an enlarged view

      Fig. Proper timing mark alignment for TDC



      Crankshaft pulley, using SST 09960-10010
       
      Belt tensioner
       
      Water pump pulley, if equipped, and pump
       
      Transverse engine mounting bracket
       
      Crankshaft Position (CKP) sensor
       
      No. 1 chain tensioner assembly, making sure not to revolve the crankshaft without the tensioner
       
      Timing chain cover. The cover is retained with 11 bolts and nuts and a Torx® stud bolt. Pry the cover between the cylinder head and block to remove it.

      Click image to see an enlarged view

      Fig. Timing chain cover mounting-1ZZ-FE engine shown, 2ZZ-GE similar

       
      Timing gear cover oil seal
       
      CKP sensor plate No. 1
       
      Timing chain tensioner slipper
       



      Timing chain sub-assembly. Remove the chain with the crankshaft gear, using screwdrivers as shown.

      Click image to see an enlarged view

      Fig. Remove the timing chain with the crankshaft gear

       

    4.  

  18.  

To install:

  1. Set the No. 1 cylinder to TDC of the compression stroke:
    1. Turn the hexagonal wrench head part of the camshafts, and align the point marks of the cam sprockets.

      Click image to see an enlarged view

      Fig. Proper alignment of the camshaft sprockets-1ZZ-FE engine



      Click image to see an enlarged view

      Fig. Proper alignment of the camshaft sprockets-2ZZ-GE engine

    2.  
    3. Using the crankshaft pulley bolt, turn the crankshaft and position the crankshaft set key upward.
    4.  

  2.  
  3. Install or connect the following:
    NOTE
    When installing the tensioner, make sure to set the hook again if the hook releases the plunger.



    Timing chain on the crank sprocket with the yellow link aligned with the mark on the crank sprocket. There are 3 yellow links on the timing chain.

    Click image to see an enlarged view

    Fig. Make sure the yellow link is aligned with the crankshaft sprocket timing mark-1ZZ-FE and 2ZZ-GE engines

     
    Crankshaft sprocket, using SST 09223-22010
     
    Timing chain on the camshaft sprockets with the yellow links aligned with the marks on the cam sprockets

    Click image to see an enlarged view

    Fig. The yellow links of the timing chain must align with the camshaft sprocket timing marks-1ZZ-FE and 2ZZ-GE engines

     
    Timing chain tensioner slipper and tighten the bolt to 14 ft. lbs. (19 Nm)
     
    Crankshaft position sensor plate, with the -F- mark facing forward
     
    Timing gear cover oil seal
     
    Timing cover. For 1ZZ-FE engine, tighten the -A- bolts to 10 ft. lbs. (13 Nm), the -B- bolts to 14 ft. lbs. (19 Nm) and the stud bolt to 84 inch lbs. (9.5 Nm), using a Torx® wrench. For 2ZZ-GE engines, tighten the M8 bolts to 15 ft. lbs. (21 m), the M6 bolts to 8 ft. lbs. (11 Nm) and the stud bolt to 84 inch lbs. (9.5 Nm).
     



    Timing chain tensioner. Torque the nuts to 80 inch lbs. (9 Nm).

    Click image to see an enlarged view

    Fig. Timing chain tensioner-1ZZ-FE engine

     
    CKP sensor and tighten the bolts to 80 inch lbs. (9 Nm)
     
    Transverse engine mounting bracket. Tighten the bolts to 35 ft. lbs. (47 Nm).
     
    Water pump and pulley
     
    Drive belt tensioner. Tighten the nut to 21 ft. lbs. (29 Nm) and the bolt to 51 ft. lbs. (69 Nm) on 1ZZ-FE engines or to 74 ft. lbs. (100 Nm) on 2ZZ-GE engines.
     

  4.  
  5. Install the crankshaft pulley, as follows:
    1. Align the pulley set key with the key groove of the pulley and slide on the pulley.
    2.  
    3. Use SST 09960-11010 to install the bolt and tighten to 102 ft. lbs. (138 Nm) for 1ZZ-FE engine or to 87 ft. lbs. (118 Nm) on 2ZZ-GE engines.
    4.  
    5. Turn the crankshaft counterclockwise and disconnect the plunger knock pin from the hook.
    6.  
    7. Turn the crankshaft clockwise and check that the slipper is pushed by the plunger. 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 plunder springs out.

      Cylinder head sub-assembly cover. Install seal packing into the locations shown and install within 3 minutes. Tighten the -A- bolts to 8 ft. lbs. (11 Nm) and the -B- bolts to 80 inch lbs. (9 Nm) for 1ZZ-FE engines. For 2ZZ-GE engines, tighten the bolts to 7 ft. lbs. (10 Nm).

      Click image to see an enlarged view

      Fig. Seal packing installation locations



      Click image to see an enlarged view

      Fig. Cylinder head (valve) cover bolt locations-1ZZ-FE engine

       
      Ignition coil assembly. Torque the bolts to 80 inch lbs. (9 Nm).
       
      Engine wire and tighten to 80 inch lbs. (9 Nm)
       
      Right side engine mount. Tighten to 38 ft. lbs. (52 Nm).
       
      Alternator bracket, 2ZZ-GE engine
       
      Alternator
       
      Vane pump, 1ZZ-FE
       
      Main cylinder head cover and tighten to 62 inch lbs. (7 Nm)
       
      Right front wheel and tire. Tighten the lug nuts to 76 ft. lbs. (103 Nm).
       

    8.  

  6.  
  7. Fill the cooling system to the proper level.
  8.  
  9. Start the vehicle, check for leaks and repair if necessary.
  10.  

 
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