Yaris 2007

Timing Chain & Front Cover

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Removal & Installation



  1. Disconnect cable from negative battery terminal.
  2.  
  3. Remove front wheel RH.
  4.  
  5. Remove engine under cover RH.
  6.  
  7. Drain engine oil.
  8.  
  9. Drain engine coolant.
  10.  
  11. Remove cylinder head cover no. 2.
  12.  
  13. Remove fan & generator v belt.
  14.  
  15. Remove generator assembly.
  16.  
  17. Remove ignition coil no. 1.
  18.  
  19. Disconnect ventilation hose.
  20.  
  21. Disconnect ventilation hose no. 2.
  22.  
  23. Remove cylinder head cover sub-assembly.
  24.  
  25. Remove engine mounting insulator sub-assembly RH.
  26.  
  27. Remove the crankshaft damper.
  28.  
  29. Remove Crankshaft Position (CKP) sensor.
  30.  
  31. Remove camshaft timing oil control valve assembly.
  32.  
  33. Remove water pump assembly.
  34.  
  35. Remove the 4 bolts and remove the transverse engine mounting bracket.

    Click image to see an enlarged view

    Fig. Removing the 4 bolts and remove the transverse engine mounting bracket

  36.  
  37. Remove the 15 bolts and the nut.
  38.  
  39. Using a screwdriver with its tip wrapped in protective tape, prize the timing cover assembly to remove it.
    NOTE
    Do not damage the contact surfaces of the oil pump assembly or oil pan sub-assembly.

  40.  
  41. Remove the 2 O-rings from the cylinder block and oil pan sub-assembly.
    NOTE
    Do not rotate the crankshaft with the chain tensioner removed. When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40°from the TDC first.

  42.  
  43. Remove chain tensioner assembly no. 1:
    1. Pull up the stopper plate and hold it with its lock released.

      Click image to see an enlarged view

      Fig. Pull up the stopper plate and hold it with its lock released

    2.  
    3. Unlock the plunger of the tensioner and push it in to the end.

      Click image to see an enlarged view

      Fig. Unlock the plunger of the tensioner and push it in to the end

    4.  
    5. Pull down the stopper plate with the plunger pushed to the end and lock the plunger.

      Click image to see an enlarged view

      Fig. Pull down the stopper plate with the plunger pushed to the end and lock the plunger

    6.  
    7. Insert a 3 mm (0.12 in.) diameter bar into the hole in the stopper plate and lock the plunger.

      Click image to see an enlarged view

      Fig. Insert a 0.12 inch diameter bar into the hole in the stopper plate and lock the plunger

    8.  
    9. Remove the 2 bolts and remove chain tensioner assembly No. 1.

      Click image to see an enlarged view

      Fig. Remove the 2 bolts and remove chain tensioner assembly No. 1

    10.  

  44.  
  45. Remove the chain tensioner slipper.
  46.  
  47. Remove the 2 bolts and remove chain vibration damper No. 1.
  48.  
  49. Remove chain sub-assembly.

    Click image to see an enlarged view

    Fig. Timing chain cover and components



    Click image to see an enlarged view

    Fig. Timing chain and related components

  50.  

To install:

  1. Make sure that all the timing marks are in the positions (TDC) shown in the illustration.
    NOTE
    The positions of the timing marks may differ from the predetermined positions due to the force of the valve spring.



    Click image to see an enlarged view

    Fig. Make sure that all the timing marks are in the positions (TDC) shown

  2.  
  3. Set the timing mark of the crankshaft in a position between 40 and 140°ATDC as illustrated.

    Click image to see an enlarged view

    Fig. Set the timing mark of the crankshaft in a position between 40 and 140°ATDC

  4.  
  5. Set the camshaft timing gear and the camshaft timing sprocket in the positions ( 20°ATDC) shown in the illustration.
  6.  
  7. Set the crankshaft in the position ( 20°ATDC) shown in the illustration.

    Click image to see an enlarged view

    Fig. Set the camshaft timing gear and the camshaft timing sprocket in the positions ( 20°ATDC) shown

  8.  
  9. Install chain vibration damper No. 1 with the 2 bolts.
  10.  
  11. Align the timing marks of the camshaft with the mark plates of the timing chain and install the timing chain.

    Click image to see an enlarged view

    Fig. Align the timing marks of the camshaft with the mark plates of the timing chain and install the timing chain

  12.  
  13. Install the chain tensioner slipper.
  14.  
  15. Install chain tensioner assembly No. 1 with the 2 bolts.
  16.  
  17. Remove the bar from chain tensioner assembly No. 1.
  18.  
  19. Install 2 new O-rings in the 2 locations shown in the illustration.

    Click image to see an enlarged view

    Fig. Install 2 new O-rings in the 2 locations shown

  20.  
  21. Apply seal packing to the oil pump assembly, cylinder head and cylinder block as shown in the illustration. Seal packing: Water pump part Toyota Genuine Seal Packing 1282B, Three Bond 1282B or Equivalent. Other part Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent

    Click image to see an enlarged view

    Fig. seal packing to the oil pump assembly, cylinder head and cylinder block as shown

  22.  
  23. Remove any oil from the contact surfaces.
  24.  
  25. Install the oil pump assembly within 3 minutes and tighten the bolts and nut within 15 minutes of applying the seal packing.
  26.  
  27. Do not expose the seal to engine oil for at least 2 hours after the installation.
  28.  
  29. Align the keyway of the oil pump rotor with the rectangular portion of the crankshaft, and slide the oil pump into place.
    NOTE
    After installing the oil pump assembly, install the mounting bracket and water pump within 15 minutes.



    Click image to see an enlarged view

    Fig. Align the keyway of the oil pump rotor with the rectangular portion of the crankshaft

  30.  
  31. Install the oil pump assembly with the 15 bolts and the nut. Tighten the bolts and nut uniformly in several steps:
    1. Bolt A: 24 ft. lbs. (32 Nm).
    2.  
    3. Bolt B: 8 ft. lbs. (11 Nm).
    4.  
    5. Bolt C: 8 ft. lbs. (11 Nm).
    6.  
    7. Bolt D: 18 ft. lbs. (24 Nm).
    8.  
    9. Bolt E: 18 ft. lbs. (24 Nm).
      NOTE
      After installing the oil pump assembly, install the mounting bracket and water pump within 15 minutes.



      Click image to see an enlarged view

      Fig. Identifying the timing cover bolts

    10.  

  32.  
  33. Install the transverse engine mounting bracket with the 4 bolts. Tighten to 41 ft. lbs. (55 Nm).
  34.  
  35. To complete installation, reverse the remaining removal procedure.
  36.  
  37. Add engine oil.
  38.  
  39. Add coolant.
  40.  
  41. Check for leaks.
  42.  

 
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