HowToRepairGuide.com: How to Replace Timing Chain on Toyota Prius?

In this chapter it contains
Timing Chain & Sprockets replacing instructions.
Timing Chain & Sprockets removal details and diagrams.
timing cover, timing chain assembly and related components diagrams and many more help to complete this task.

Timing Chain & Sprockets
REMOVAL & INSTALLATION Procedure is as follows:----

CAUTION

The hybrid system uses high voltage circuits, so improper handling could cause electric shock or leakage. During service, be sure to follow procedures.

Before servicing the vehicle, refer to the Precautions Section.

Properly relieve the fuel system pressure.

Disconnect the negative battery cable. Wait at least 90 seconds after disconnecting the negative battery cable to prevent possible airbag and seat belt pretensioner activation.

While wearing insulating gloves, slide up the lever of the service plug grip and remove while turning the lever to the left. Be sure to insulate the service plug with insulating tape.

CAUTION
Do not touch the high voltage connectors and terminals for 5 minutes after removing the service plug grip.

Exploded view of timing cover, timing chain assembly and related components-1.5L hybrid engine

Remove the outer front cowl top panel.

Remove right engine under cover.

Drain the engine coolant.

Remove or disconnect the following:

Air cleaner assembly

Brake fluid level sensor connector

Brake fluid reservoir tank mounting bolts (2) and suspend it with rope

Brake fluid reservoir tank bracket

Ignition connectors (4)

Fuel injector connectors (4)

Vacuum Switching Valve (VSV) connectors (2)

Camshaft Position (CMP) sensor connector

Water temperature connector

Camshaft timing oil control valve connector

Air cleaner inlet hose

Engine coolant reservoir tank

VSV from engine mounting insulator

Accessory drive belt

Place a floor jack under the engine to support it, with a block of wood between the engine and the jack.

Remove or disconnect the following:

Right engine mounting insulator

Engine wiring from cylinder head cover

Ignition coils (4)

PCV hoses (2)

7 bolts, 2 seal washers, 2 nuts, cylinder head cover and gasket

Set the No. 1 cylinder to Top Dead Center/compression by turning the crankshaft pulley and aligning its groove with timing mark -0- of the timing chain cover.

Fig. Aligning both timing marks on the camshaft timing sprocket and valve timing controller assembly-1.5L hybrid engine

Check that both timing marks on the camshaft timing sprocket and valve timing controller assembly are facing right up. If not, turn the crankshaft 1 revolution (360 degrees) and align the marks.

Remove the crankshaft pulley bolt and the crankshaft pulley.

Remove or disconnect the following:

Crankshaft Position (CKP) sensor

Right engine mounting bracket

Water pump

Oil control valve

Timing chain cover

Chain tensioner

Chain tensioner slipper

Chain vibration damper

Timing chain

To install:

Install the timing chain.

After setting the crankshaft at ATDC 40-140 degrees, set cams of intake and exhaust timing sprockets at ATDC 20 degrees and then the reset the crankshaft at ATDC 20 degrees.

Install the chain vibration damper with the 2 bolts and tighten to 80 inch lbs. (9 Nm).

Fig. Align the match marks of timing chain mark plate (Yellow), camshaft timing sprocket, camshaft timing gear and crankshaft timing sprocket-1.5L hybrid engine

Align the match marks of timing chain mark plate (Yellow), camshaft timing sprocket, camshaft timing gear and crankshaft timing sprocket to install the timing chain. To prevent the exhaust camshaft from spring back, turn it using a wrench and set it at the mark on a chain.

Install the chain tensioner slipper.

While rotating the lock plate of the tensioner up-ward, push in the plunger of the tensioner.

While rotating the lock plate of the tensioner down-ward, insert a bar of 0.098 inch (2.5mm) into the holes in the lock plate.

Install the chain tensioner with the 2 bolts and tighten to 80 inch lbs. (9 Nm).

Remove the bar from the chain tensioner.

Check that the tension between the intake and exhaust camshaft timing sprocket.

Fig. Apply seal packing to the timing chain cover-1.5L hybrid engine

Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block. Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. Thoroughly clean all components to remove all the loose material. Using a non-residue solvent, clean both sealing surfaces.

Apply seal packing to the timing chain cover. Install a nozzle that has been cut to a 0.16-0.20 inch (4-5mm) opening. FIPG shall be accumulated in the groove for FIPG to a depth of 0.10 inch (2.5mm) or more. Avoid applying an excessive amount to the surface. Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap.

Fig. Apply seal packing to 4 locations-1.5L hybrid engine

Apply seal packing to 4 locations. Install a nozzle that has been cut to a 0.16-0.20 inch (4-5mm) opening. Avoid applying an excessive amount to the surface. Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap.

Install 2 new O-rings to the cylinder block and oil pan No. 1.

Fig. Correct installation of the timing chain cover and water pump bolts and nuts-1.5L hybrid engine

Install the timing chain cover, new O-ring and water pump with the 16 bolts and 3 nuts. Uniformly tighten the bolts and nut in several passes to the following torque values:

NOTE
Pay attention not to wrap the chain and slipper over the chain cover seal line. After installing the chain cover, must install the mounting bracket and water pump within 15 minutes.

Bolt A, 0.787 inch (20mm)-8 ft. lbs. (11 Nm)

Bolt B, 1.181 inch (30mm)-18 ft. lbs. (24 Nm)

Bolt C, 1.378 inch (35mm)-8 ft. lbs. (11 Nm)

Bolt D, 0.787 inch (20mm)-18 ft. lbs. (24 Nm)

Bolt E, 1.378 inch (35mm)-8 ft. lbs. (11 Nm)

Nut F-18 ft. lbs. (24 Nm)

Nut G-8 ft. lbs. (11 Nm)

Apply seal packing to threads of the engine mounting bracket mounting bolt, but do not apply seal packing to 2 or 3 threads of the bolt end.

Install the right mounting bracket with the 4 bolts and tighten to 41 ft. lbs. (55 Nm).

Install the crankshaft position sensor and tighten the bolt at the sensor to 66 inch lbs. (7.5 Nm), and the other bolts to 8 ft. lbs. (11 Nm).

Install the oil control valve and tighten to 66 inch lbs. (7.5 Nm).

Install the crankshaft pulley as follows:
1. Clean the crankshaft pulley inside.
2. Install the pin to the crankshaft.
3. Align the hole in the crank pulley with the pin position and install the crank pulley.
4. Using SST 09213-70011 and 09330-00021, install the pulley bolt and tighten to 94 ft. lbs. (128 Nm).
  
  Fig. Apply seal packing to 2 locations as shown-1.5L hybrid engine

Remove any old packing (FIPG) material and apply seal packing to 2 locations as shown in the illustration.

Install the gasket to the cylinder head cover.

NOTE
Part must be assembled within 3 minutes of seal packing application. Otherwise the material must be remove and reapplied.

Install the cylinder head cover and cable bracket with the 7 bolts, 2 seal washers and 2 nuts. Uniformly tighten the bolts and nuts, in the several passes, in the sequence to 7 ft. lbs. (10 Nm).