Timing chain replacement: Toyota Yaris 2005 (2ZR-FE)

🧭 Before you start

Fits: platform codes 1.8, 16V, VVT-I, TS

• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: locking pin

Don't miss

• Do not rotate the crankshaft
• Use a wrench to counterhold the inlet camshaft
• The cover must be fitted within 5 minutes of applying the sealant

🔧 Engine codes this applies to

📋 Procedure

Preparation and removal

1. Remove the engine hangers
2. Remove the oil filler cap
3. Remove the spark plugs
4. Note: Avoid bending, torsion or traction
5. Position the crankshaft as shown

6. Turn the pump shaft until the position is as shown
7. Turn the crankshaft until the locking pin fits
8. Turn the crankshaft anti-clockwise
9. Position the crankshaft as shown
10. Remove the crankshaft pulley centre bolt
11. Turn the crankshaft to TDC for cylinder 1
12. Counterhold tool:
13. Loosen the crankshaft pulley centre bolt
14. Use the special tools
15. Remove the crankshaft pulley centre bolt
16. Remove the crankshaft pulley
17. Use the special tool
18. Remove the chain tensioner
19. Note: Do not rotate the crankshaft
20. Crankshaft position sensor:
21. Remove the crankshaft position sensor
22. Oil pressure switch:
23. Remove the oil pressure switch
24. Remove the knock sensor
25. Remove the coolant temperature sensor
26. Remove the oil filter with bracket
27. Remove the thermostat
28. Use a wrench to counterhold the inlet camshaft
29. Remove the timing chain cover
30. Remove the coolant pump
31. Remove the timing chain upper guide rail
32. Turn the camshaft gearwheel anti-clockwise to slacken the chain
33. Timing chain:
34. Remove the timing chain
35. Turn the crankshaft 90° clockwise
36. Remove the oil pump chain together with the gearwheels

Installation and checks

37. Renew the gaskets
38. Fit the oil pump timing chain and gearwheels together
39. Tighten the nut by hand
40. Remove the locking pin
41. Refit the chain guide rail
42. Temporarily fit the crankshaft pulley bolt
43. Check the camshaft timing marks
44. Fit the timing chain onto the exhaust camshaft gearwheel
45. Check the timing marks
46. If the marks are misaligned, rotate the engine 1 turn
47. Renew the gasket
48. Renew the O-rings
49. Fit the timing chain onto the inlet camshaft gearwheel
50. Turn the camshaft gearwheel clockwise to its stop
51. Fit the timing chain onto the crankshaft gearwheel
52. Use a wrench to counterhold the inlet camshaft
53. Note: Apply sealant before fitting
54. Note: The cover must be fitted within 5 minutes of applying the sealant
55. Apply sealant as indicated
56. Refit the timing chain cover
57. Fit the locking pin
58. Bolts:
59. Tighten the bolts by hand
60. Bolt:
61. Remove the nut
62. Tighten the bolts
63. Tighten in the order shown
64. Timing chain tensioner:
65. Refit the chain tensioner
66. Crankshaft pulley
67. Oil filter
68. Valve cover
69. Camshaft position sensor
70. Tighten the nuts
71. Turn the crankshaft anti-clockwise
72. Note: This will release the plunger from the hook
73. The plunger should be released
74. Turn the crankshaft clockwise
75. The plunger should be extended

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