EG-37 ENGINE MECHANICAL TIMING BELT COMPONENTS FOR REMOVAL AND INSTALLATION 2JZ-GE

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1 ENGINE EG37 TIMING BELT COMPONENTS FOR REMOVAL AND INSTALLATION 2JZGE

2 EG38 ENGINE 2JZ GTE

3 ENGINE EG39 TIMING BELT REMOVAL (See Components for Removal and Installation) 1. REMOVE BATTERY AND BATTERY TRAY CAUTION: Work must be started after 90 seconds from the time the ignition switch is truned to the LOCK position and the negative () terminal cable is disconnceted from the battery. 2. REMOVE ENGINE UNDER COVER 3. 2JZ GTE: REMOVE NO.2 AIR TUBE Loosen the 2 hose clamps, and remove the 2 bolts and air tube. 4. DRAIN ENGINE COOLANT 5. REMOVE AIR CLEANER DUCT Remove the bolt and air cleaner duct. 6. 2JZ GTE: REMOVE NO.5 AIR HOSE Loosen the 2 hose clamps and remove the air hose. 7. REMOVE LH HEADLIGHT BEAM ANGLE GAUGE Remove the screw and beam angle gauge.

4 EG40 ENGINE 8. REMOVE NO.2 FAN SHROUD (a) Remove the 2 clips. (b) Disconnect the claw of the No.2 fan shroud from the hook of the No. 1 fan shroud, and remove the No.2 fan shroud. 9. REMOVE RADIATOR ASSEMBLY (a) 2JZGTE: Disconnect the ECT switch (for electric cooling fan) connector and wire harness. (b) 2JZGTE: Disconnect the electric cooling fan connector and wire harness. (c) Disconnect the following hoses: (1) Reservoir tank inlet hose from radiator (2) Upper radiator hose from front water outlet (3) Lower radiator hose from radiator (4) A/T: 2 oil cooler hoses from radiator Plug the hose ends. (d) Remove the bolt and upper radiator support. Remove the 2 upper radiator supports. (e) Lift out the radiator assembly.

5 ENGINE EG JZ GTE M/T: REMOVE DRIVE BELT TENSIONER DAMPER Remove the 2 nuts and tensioner damper. 11. REMOVE DRIVE BELT. FAN, FLUID COUPLING AS SEMBLY AND WATER PUMP PULLEY (a) Loosen the 4 nuts holding the fluid coupling to the water pump. (b) Loosen the drive belt tension by turning the drive belt tensioner clockwise, and remove the drive belt. (c) Remove the 4 nuts, the fan, fluid coupling assembly and water pump pulley. 12. REMOVE NO.3 TIMING BELT COVER (a) Remove the oil filler cap. (b) 2JZGE: Using a 5 mm hexagon wrench, remove the 6 bolts and belt cover. (c) 2JZGTE: Using a 5 mm hexagon wrench, remove the 10 bolts and belt cover.

6 EG42 ENGINE 13. REMOVE NO.2 TIMIING BELT COVER Using a 5 mm hexagon wrench, remove the 3 bolts, belt cover and gasket. 14. REMOVE DRIVE BELT TENSIONER Remove the 3 bolts and tensioner. 15. SET NO.1 CYLINDER TO TDC/COMPRESSION (a) Turn the crankshaft pulley and align its groove with timing mark 0 of the No.1 timing belt cover. NOTICE: Always turn the crankshaft clockwise. (b) Check that the timing marks of the camshaft timing pulleys are aligned with the timing marks of the No.4 timing belt cover. If not, turn the crankshaft one revolution (360 ). 16. REMOVE TIMING BELT FROM CAMSHAFT TIMING PULLEYS HINT (Reusing timing belt): Place matchmarks on the timing belt and camshaft timing pulleys as shown in the illustration.

7 ENGINE EG43 (a) Alternately loosen the 2 bolts, and remove them, the tensioner and dust boot. (b) Disconnect the timing belt from the camshaft timing pulleys. 17. REMOVE CAMSHAFT TIMING PULLEYS Using SST, remove the bolt for the timing pulley. Remove both timing pulleys. SST ( ) 18. A/T: DISCONNECT 41L COOLER TUBES Remove the 2 bolts and hose clamps and disconnect oil cooler tubes. 19. REMOVE CRANKSHAFT PULLEY (a) Using SST, loosen the pulley bolt. SST , (b) Remove the SST and pulley bolt.

8 EG44 ENGINE (c) Using SST, remove the pulley. SST JZ G E: REMOVE PS PUMP FRONT BRACKET Remove the 3 bolts, plate washer and pump front bracket. 21. REMOVE No.1 TIMING BELT COVER Remove the 5 bolts, timing belt cover and gasket. 22. REMOVE TIMING BELT GUIDE 23. REMOVE TIMING BELT HINT (When reusing timing belt): Draw an arrow on the timing belt in the direction of engine revolution, and place matchmarks on the timing belt and crankshaft timing pulley.

9 ENGINE EG REMOVE IDLER PULLEY Using a 10 mm hexagon wrench, remove the pivot bolt, plate washer and idler pulley. 25. REMOVE CRANKSHAFT TIMING PULLEY (a) 2JZGTE: Remove the bolt and timing belt plate. (b) Remove the crankshaft timing pulley. If the pulley cannot be removed by hand, use SST to remove the crankshaft timing pulley. SST ( , , , ) TIMING BELT COMPONENTS INSPECTION 1. INSPECTION TIMING BELT NOTICE: Do not bend, twist or turn the timing belt inside out. Do not allow the timing belt to come into contact with oil, water or steam. Do not utilize timing belt tension when installing or removing the mount bolt of the camshaft timing pulley. If there are any defects, as shown in the illustrations, check the following points. (a) Premature parting Check for proper installation. Check the timing cover gasket for damage and proper installation.

10 EG46 ENGINE (b) If the belt teeth are cracked or damaged, check to see if either camshaft is locked. (c) If there is noticeable wear or cracks on the belt face, check to see if there are nicks on the side of the idler pulley lock. (d) If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley. (e) If there is noticeable wear on the belt teeth, check timing cover for damage and check gasket has been installed correctly and for foreign material on the pulley teeth. If necessary, replace the timing belt. 2. INSPECT IDLER PULLEY Check the turning smoothness of the idler pulley. If necessary, replace the idler pulley.

11 ENGINE EG47 3. INSPECT DRIVE BELT TENSIONER Check the turning smoothness of the tensioner. If necessary, replace the tensioner. 4. INSPECT TIMING BELT TENSIONER (a) Visually check tensioner for oil leakage. HINT: If there is only the faintest trace of oil on the seal on the push rod side, the tensioner is all right. If leakage is found, replace tensioner. (b) Hold the tensioner with both hands and push the push rod strongly against the floor or wall to check that it doesn t move. If the push rod moves, replace the tensioner. (c) Measure the protrusion of the push rod from the housing end. Protrusion: mm( in.) If the protrusion is not as specified, replace the tensioner. 5. 2JZ GTE M/T: INSPECT DRIVE BELT TENSION DAMPER Compress and extend the tension damper rod and check that there is no abnormal resistance or unusual operation sounds. If there is any abnormality, replace the tension damper with a new one.

12 EG48 ENGINE NOTICE: When discarding the tension damper, use the following procedure. (1) Fully extend the damper rod. (2) Using a drill, make a hole in the cylinder as shown to the gas inside. CAUTION: The gas coming out is harmless, but be careful of the chips which may fly up when drilling. TIMING BELT INSTALLATION (See Components for Removal and Installation) 1. INSTALL CRANKSHAFT TIMING PULLEY (a) Align the pulley set key with the key groove of the pulley. (b) Slide on the timing pulley facing the flange side inward. (c) 2JZGTE: Install the timing belt plate with the bolts. Torque: 7.8 Nm (80 kgfcm, 69 in.lbf) 2. INSTALL IDLER PULLEY (a) Apply adhesive to 2 or 3 threads of the pivot bolt. Adhesive: Part No THREE BOND 1344, LOCTITE 242 or equivalent (b) Using a 10 mm hexagon wrench, install the plate washer and pulley with the pivot bolt. Torque: 34 Nm (350 kgf/cm, 25 ftlbf) (c) Check that the pulley bracket moves smoothly. 3. TEMPORARILY INSTALL TIMING BELT NOTICE: The engine should be cold. (a) Use the crankshaft pulley bolt to turn the crankshaft and align the timing marks on the crankshaft timing pulley and on the oil pump body. (b) Remove any oil or water on the crankshaft timing pulley and idler pulley, and keep them clean.

13 ENGINE EG49 (c) Install the timing belt on the crankshaft timing pulley and idler pulley. HINT (When reusing timing belt): Align the match marks of the crankshaft timing pulley and timing belt, and install the belt with the arrow pointing in the direction of engine revolution. 4. INSTALL TIMING BELT GUIDE Install the guide, facing the cup side outward. 5. INSTALL NO.1 TIMING BELT COVER (a) Install the gasket to the timing belt cover. (b) Install the timing belt cover with the 5 bolts. 6. 2JZGE: INSTALL PS PUMP FRONT BRACKET (a) Install the pump front bracket with the 2 bolts. Torque: 58 Nm (590 kgfcm, 43 ftlbf) (b) install the plate washer and bolt to the oil pump. Torque: 52 Nm (530 kgfcm, 38 ftlbf) 7. INSTALL CRANKSHAFT PULLEY (a) Align the pulley set key with the key groove of the pulley, and slide on the pulley. (b) Using SST, install and torque the bolt. SST , Torque: 324 Nm (3,300 kgfcm, 239 ftlbf)

14 EG50 ENGINE 8. A/T: CONNECT OIL COOLER TUBES Install the hose clamps, 2 bolts and oil cooler tubes. 9. INSTALL CAMSHAFT TIMING PULLEYS (a) Align the camshaft knock pin with the groove on the pulley, and slide on the timing pulley. (b) Temporarily install the timing pulley bolt. (e) Using SST to hold the pulley, torque the pulley bolt. SST ( ) Torque: 79 Nm (810 kgfcm, 59 ftlbf) 10. SET NO.1 CYLINDER TO TDC/COMPRESSION (a) Turn the crankshaft pulley, and align its groove with the timing mark 0 of the No.1 timing belt cover. NOTICE: Always turn the crankshaft clockwise. (b) Using SST, align the timing marks of the camshaft timing pulleys and No.4 timing belt cover. SST ( )

15 ENGINE EG INSTALL TIMING BELT HINT (When reusing timing belt): Align the matchmarks of the timing belt and camshaft timing pulleys. (a) Remove any oil or water on the camshaft timing pulley, and keep it clean. (b) Install the timing belt, checking the tension between the crankshaft timing pulley and exhaust camshaft timing pulley. 12. SET TIMING BELT TENSIONER (a) Using a press, slowly press in the push rod using 981 9,807 N (1100 1,000 kgf, 220 2,205 lbf) of force. (b) Align the holes of the push rod and housing, pass a 1.5 mm hexagon wrench through the holes to keep the push rod retracted. (c) Release the press. (d) Install the dust boot onto the tensioner. 13. INSTALL TIMING BELT TENSIONER (a) Temporarily install the tensioner with the 2 bolts. (b) Alternately tighten the 2 bolts. Torque: 26 Nm (270 kgfcm, 20 ftlbf)

16 EG52 ENGINE (c) Remove the 1.5 mm hexagon wrench from the tensioner with pliers. 14. CHECK VALVE TIMING (a) Slowly turn the crankshaft pulley 2 revolutions from TDC to TDC. NOTICE: Always turn the crankshaft clockwise. (b) Check that each pulley aligns with the timing marks as shown in the illustration. If the marks do not align, remove the timing belt and reinstall it. 15. INSTALL DRIVE BELT TENSIONER Install the tensioner with the 3 bolts. Torque: 21 Nm (210 kgfcm, 15 ftlbf) NOTICE: Be careful not to drop the bolts inside the timing belt cover. 16. INSTALL NO.2 TIMING BELT COVER (a) Install the gasket on the belt cover. (b) Using a 5 mm hexagon wrench, install the belt cover with the 3 bolts.

17 ENGINE EG INSTALL NO.3 TIMING BELT COVER (a) 2JZGE: Using a 5 mm hexagon wrench, install the belt cover with the 6 bolts. (b) 2JZGTE: Using a 5 mm hexagon wrench, install the belt cover with the 10 bolts. (c) Install the oil filler cap. 18. INSTALL WATER PUMP PULLEY, FAN, FLUID COU PLING ASSEMBLY AND DRIVE BELT (a) Align the matchmarks, and install the water pump pulley, the fan and fluid coupling assembly with the 4 nuts. (b) Install the drive belt by turning the drive belt tensioner clockwise. (c) Stretch the belt tight and tighten the 4 nuts. Torque: 16 Nm (165 kgfcm, 12 ftlbf)

18 EG54 ENGINE 19. 2JZ GTE M/T: INSTALL DRIVE BELT TENSIONER DAMPER Install the tensioner damper with the 2 nuts. Torque: 20 Nm (200 kgfcm, 14 ftibf) 20. INSTALL RADIATOR ASSEMBLY (a) Place the radiator assembly on the body bracket. (b) Install the radiator with the 2 upper radiator suports and 2 bolts. Torque: 15 Nm (155 kgfcm, 11 ftlbf) HINT: After installation, check that the rubber cushion (A) of the support is not depressed. (c) Connect the following hoses: (1) Reservoir tank inlet hose to radiator (2) Upper radiator hose to water outlet (3) Lower radiator hose to radiator (4) A/T: 2 oil cooler hoses to radiator (d) 2JZGTE: Connect the electric cooling fan connector and wire harness. (e) 2JZGTE: Connect the ECT switch (for electric cooling fan) connector and wire harness.

19 ENGINE EG INSTALL NO.2 FAN SHROUD (a) Connect the claw of the No.2 fan shroud from the hook of the No.1 fan shroud. (b) Install the No.2 fan shroud with the 2 clips. 22. INSTALL LH HEADLIGHT BEAM ANGLE GAUGE Instal! the beam angle gauge with the screw JZ GTE: INSTALL No.5 AIR HOSE Install the air hose with the 2 hose clamps. 24. INSTALL AIR CLEANER DUCT (a) Connect the air cleaner duct to the air cleaner cap. (b) Install the air cleaner duct with the bolt JZ GTE: INSTALL NO.2 AIR TUBE (a) Connect the air tube to the air hoses. (b) install the air tube with the 2 clamps and 2 bolts.

20 EG56 ENGINE 26. FILL ENGINE WITH COOLANT 27. A/T: CHECK AUTOMATIC TRANSMISSION FLUID LEVEL (See page MA18 ) 28. INSTALL BATTERY TRAY AND BATTERY 29. START ENGINE CHECK FOR LEAKS 30. CHECK IGNITION TIMING (See page EG27 or EG29 ) 31. INSTALL ENGINE UNDER COVER 32. PERFORM ROAD TEST Check for abnormal noise, shock, slippage, correct shift points and smooth operation. 33. RECHECK ENGINE COOLANT LEVEL

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