Timing chain replacement: Toyota Avensis T25 (2AZ-FSE)

🧭 Before you start

Fits: platform codes 2.4, 16V, VVT-I

• Opens: engine oil, power steering fluid
• Timing position: the crankshaft or camshaft is set and locked during this job

Don't miss

• Start the engine after it has stopped for at least 5 seconds to ensure the fuel pressure is released

🔧 Engine codes this applies to

📋 Procedure

Preparation and removal

1. Remove the rear seat
2. Insert a suitable tool
3. Turn the crankshaft clockwise to align the crankshaft key with the top
4. Until the engine stalls
5. Note: Start the engine after it has stopped for at least 5 seconds to ensure the fuel pressure is released

6. Turn the ignition off
7. Power steering pump
8. Ignition coil
9. Remove the radiator cover
10. Remove the engine lower covers
11. Remove the engine upper cover
12. Remove the fuel pump vibration damper
13. Use a special tool
14. Remove the high-pressure pump
15. Remove the ancillary drive belt
16. Remove the alternator
17. Remove the exhaust pipes
18. Drain the power steering fluid
19. Remove the power steering pump
20. Use a special tool
21. Disconnect the power steering lines
22. Remove the power steering fluid reservoir
23. Remove the power steering fluid reservoir bracket
24. Disconnect the air-conditioning line(s)
25. Disconnect the engine wiring
26. Remove the bracket
27. Remove the ignition coils
28. Disconnect the positive crankcase breather hoses from the valve cover
29. Remove the valve cover
30. Turn the crankshaft to TDC for cylinder 1
31. Align the crankshaft timing marks
32. Align the camshaft timing marks
33. If the marks are misaligned, rotate the engine 1 turn
34. Place the jack under the engine sump
35. Remove the right-hand engine support bracket
36. Remove the right-hand engine support
37. Loosen the crankshaft pulley centre bolt
38. Use the special tools
39. Remove the crankshaft pulley centre bolt
40. Remove the crankshaft pulley
41. Use the special tool
42. Remove the chain tensioner
43. Remove the crankshaft position sensor
44. Remove the oil sump
45. Use a special tool to cut the sealant
46. Remove the ancillary drive belt tensioner pulley
47. Remove the timing chain cover
48. Remove the chain tensioner rail
49. Remove the chain guide rail
50. Remove the crankshaft position sensor plate
51. Remove the lower timing chain guide
52. Remove the timing chain
53. Remove the crankshaft gearwheel
54. Turn the crankshaft 90° anti-clockwise
55. Align the timing marks on the second timing chain
56. Insert a suitable tool and remove the nut
57. Diameter
58. Remove the tensioner
59. Remove the second chain

Installation and checks

60. Refit all parts in the reverse order of removal
61. Vibration damper
62. Fit the second timing chain
63. Tighten the oil pump gearwheel
64. Refit the chain guide rail
65. Engine oil drain plug
66. Reconnect the fuel pump connector
67. Refit the rear seat
68. Refit the timing chain cover
69. Bend the tab as shown to push in the plunger and lock it with the hook
70. Refit the chain tensioner
71. Tighten the nuts
72. Turn the crankshaft anti-clockwise
73. Note: This will release the plunger from the hook
74. The plunger should be released
75. Turn the crankshaft clockwise
76. The plunger should be extended
77. Refill the engine oil
78. Refill the power steering system
79. Bleed the power steering system
80. Check the fluid level

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