Timing chain replacement

Tiny
PAPPA_SMURF
  • MEMBER
  • 2008 TOYOTA RAV4
  • 2.0L
  • 4 CYL
  • 2WD
  • AUTOMATIC
  • 110,000 MILES
Hi,

Voxy 3ZR-FAE (Valvematic) as the engine is the same I think?
My Car is a Japanese import to Mozambique.
I need to do an in car timing chain replacement and am having trouble getting the relevant data for this.
I have removed all the wiring, injectors, plugs, Tappet cover, Oil filter, alternator, crank pulley.
Please could you help. I include the spec I have for the car.

Production period 06.2007 - 04.2010
Catalog code 651170
Complexation ZRR70W-BRXSP
Frame number ZRR70-0109742
Characteristics Engine Body Grade Transm. Options
3ZRFAE ZS VOXY 08S CBU HTWVM
Color code: 1F7 Trim code: FG19 Manufacture date: 2008.04

Any help will be appreciated.
Safe Christmas to all.
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Saturday, December 26th, 2020 AT 1:11 AM

7 Replies

Tiny
JACOBANDNICKOLAS
  • EXPERT
Hi,

This vehicle isn't offered in the US, so I have no technical information related to it. However, I can try my best to help.

I need some general information. First, is it a single or dual overhead cam engine? Also, does it have variable valve timing? When you took it apart, did you have it on top dead center and note the position of the timing marks?

Here is a link you may find of interest:

https://www.2carpros.com/articles/how-a-timing-belt-works

Let me know.

Joe
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Sunday, December 27th, 2020 AT 9:27 PM
Tiny
PAPPA_SMURF
  • MEMBER
Hi,

Thanks for the reply.
The motor should be the same as in the Toyota Rav 4 3rd edition?
The concerns I have are:
According to this site, https://toyota.epc-data.com/noah/zrr70w/184295/?frame_no=ZRR70-0109742&ref=. the engine is an 3ZR-AFE, but in my photos, included, there should be a bridge piece between the cam gears, but my engine does not have it? as per the website (confusing). I must still remove the water pump and cover to see any other anomalies.
I have removed the crank pulley by bumping the starter as I don't have the SST, so I will put it back to get TDC before I continue.
I desperately need the correct steps to do the whole job properly, I do not have access to electronic repair manual.
Your help is very much appreciated.
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Monday, December 28th, 2020 AT 11:28 PM
Tiny
JACOBANDNICKOLAS
  • EXPERT
In 2008, the Rav 4 didn't come with a 2.0. It came with a 2.4L. Here are the directions for the removal and replacement of the chain. See if it helps. The attached pics correlate with the directions.

__________________________________________

Here is the removal information. Note that this is a 2.4L

_________________________________________

2008 Toyota Truck RAV4 2WD L4-2.4L (2AZ-FE)
Removal
Vehicle Engine, Cooling and Exhaust Engine Timing Components Timing Chain Service and Repair Removal and Replacement Removal
REMOVAL
2AZ-FE ENGINE MECHANICAL: TIMING CHAIN: REMOVAL

REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

2. REMOVE RADIATOR SUPPORT OPENING COVER
3. REMOVE FRONT WHEEL RH
4. REMOVE NO. 1 ENGINE UNDER COVER
5. REMOVE FRONT FENDER APRON RH
6. REMOVE NO. 1 ENGINE COVER

pic 1

(a)Remove the 2 nuts and cover.
7. DRAIN ENGINE OIL See: Engine Oil > Removal and Replacement > Replacement

8. REMOVE FRONT EXHAUST PIPE See: Exhaust Pipe > Removal and Replacement > Removal

9. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH See: Drive Belt > Removal and Replacement > Removal

10. REMOVE FAN AND GENERATOR V BELT See: Drive Belt > Removal and Replacement > Removal

11. REMOVE GENERATOR ASSEMBLY

12. REMOVE RADIATOR RESERVOIR

pic 2

(a)Remove the 2 bolts and radiator reservoir.
13. REMOVE ENGINE MOUNTING INSULATOR RH

pic 3

(a)Remove the bolt of the wire harness protector.
(b)Disconnect the 2 clamps of the engine wire.

Pic 4

(c)Place a transmission jack underneath the engine, then put a wooden block on the jack.

Pic 5

(d)Remove the 4 bolts, 2 nuts and engine mounting insulator RH.
NOTE: Do not apply excessive force to the return tube when removing the engine mounting insulator RH.
HINT: Keep clearance by lowering the engine using the transmission jack when removing the engine mounting insulator FR.

14. REMOVE ENGINE MOUNTING INSULATOR FR

pic 6

(a)Remove the through bolt and nut.

Pic 7

(b)Remove the 2 bolts and engine mounting insulator FR.
HINT: Keep clearance by lowering the engine using the transmission jack when removing the engine mounting insulator FR.

15. REMOVE IDLER PULLEY

pic 8

(a)Loosen the 2 bolts and remove the idler pulley with the 2 bolts.
16. REMOVE IGNITION COIL ASSEMBLY See: Ignition Coil > Removal and Replacement > Removal

17. REMOVE SPARK PLUG See: Valve Clearance > Adjustments > Adjustment

18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

pic 9

(a)Disconnect the 2 ventilation hoses form the cylinder head cover.

Pic 10

(b)Remove the 2 bolts and disconnect the 2 engine wires.

Pic 11

(c)Remove the 8 bolts, 2 nuts and cylinder head cover.
19. REMOVE OIL PAN SUB-ASSEMBLY

pic 12

(a)Install the No. 1 and No. 2 engine hangers with the bolts.
Torque: 38 Nm (387 kgf-cm, 28 ft-lbf)

pic 13

(b)Attach the sling device to the engine hangers and chain block.

Pic 14

(c)Remove the 12 bolts and 2 nuts.

Pic 15

(d)Insert the blade of oil pan seal cutter between the crankcase, chain cover and oil pan, then cut off the applied sealer and remove the oil pan.
NOTE: Be careful not to damage the contact surface of the crankcase, chain cover and oil pan.

20. SET NO. 1 CYLINDER TO TDC/COMPRESSION

pic 16

(a)Turn the crankshaft pulley until its groove and the timing mark "0" of the timing chain cover are aligned.
(b)Check that each timing mark of the camshaft timing gear and sprocket is aligned with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration.
If not, turn the crankshaft by 1 revolution (360 ) to align the timing marks as above.
21. REMOVE CRANKSHAFT PULLEY

pic 17

(a)Using SST, fix the pulley in place and loosen the pulley bolt.
SST: 09213-54015
91651-60855
SST: 09330-00021

pic 18

(b)Remove the crankshaft pulley.
HINT: If necessary, remove the pulley and pulley bolt using SST.

SST: 09950-50013
09951-05010
09952-05010
09953-05020
09954-05021
SST: 09950-40011
09957-04010
22. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

pic 19

(a)Remove the 2 nuts, chain tensioner and gasket.
NOTE: Do not turn the crankshaft without the chain tensioner.

23. REMOVE ENGINE MOUNTING BRACKET RH

pic 20

(a)Remove the 3 bolts and engine mounting bracket RH.
24. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(a)Lift the engine upward using the transmission jack.
NOTE: Do not lift the engine more than necessary.

Pic 21

(b)Remove the bolt, nut and V-ribbed belt tensioner.
25. REMOVE CRANKSHAFT POSITION SENSOR See: Crankshaft Position Sensor > Removal and Replacement > Removal

26. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

pic 23

(a)Using an E10 "TORX" socket, remove the stud bolt for the V-ribbed belt tensioner.

Pic 24

(b)Remove the 12 bolts and 2 nuts.

Pic 25

(c)Remove the timing chain cover by prying the portions between the timing chain cover, cylinder head and cylinder block with a screwdriver.
NOTE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder head and cylinder block.

Pic 26

27. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE
28. REMOVE TIMING CHAIN GUIDE

pic 27

(a)Remove the bolt and timing chain guide.
29. REMOVE CHAIN TENSIONER SLIPPER

pic 28

(a)Remove the bolt and chain tensioner slipper.
30. REMOVE NO. 1 CHAIN VIBRATION DAMPER

pic 29

(a)Remove the 2 bolts and chain vibration damper.

Pic 30

31. REMOVE CHAIN SUB-ASSEMBLY

pic 31

32. REMOVE CRANKSHAFT TIMING SPROCKET
33. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

pic 32

(a)Turn the crankshaft by 90 counterclockwise to align the adjusting hole of the oil pump drive shaft sprocket with the groove of the oil pump.

Pic 33

(b)Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft sprocket to lock the gear in position, and then remove the nut.

Pic 34

(c)Remove the bolt, chain tensioner plate and spring.
(d)Remove the oil pump drive sprocket, oil pump drive shaft sprocket and No. 2 chain.

_________________________________________

Install

2008 Toyota Truck RAV4 2WD L4-2.4L (2AZ-FE)
Installation
Vehicle Engine, Cooling and Exhaust Engine Timing Components Timing Chain Service and Repair Removal and Replacement Installation
INSTALLATION
2AZ-FE ENGINE MECHANICAL: TIMING CHAIN: INSTALLATION

INSTALLATION

1. INSTALL NO. 2 CHAIN SUB-ASSEMBLY

pic 35

(a) Set the crankshaft key in the left horizontal position.
(b) Turn the cutout of the drive shaft so that it faces upward.

Pic 36

(c) Align the yellow mark links with the timing marks of each gear as shown in the illustration.
(d) Install the sprockets onto the crankshaft and oil pump shaft with the chain wrapped on the gears.
(e) Temporarily tighten the oil pump drive shaft sprocket with the nut.

Pic 37

(f) Insert the damper spring into the adjusting hole, and then install the chain tensioner plate with the bolt.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)

pic 38

(g) Align the adjusting hole of the oil pump drive shaft sprocket with the groove of the oil pump.
(h) Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, and then tighten the nut.
Torque: 29.5 Nm (301 kgf-cm, 22 ft-lbf)

pic 39

2. INSTALL CRANKSHAFT TIMING SPROCKET
3. INSTALL NO. 1 CHAIN VIBRATION DAMPER

pic 40

(a) Install the chain vibration damper with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
4. INSTALL CHAIN SUB-ASSEMBLY

pic 41

(a) Set the No. 1 cylinder to TDC/compression.
(1) Turn the camshafts with a wrench (using the hexagonal lobe) to align the timing marks of the camshaft timing gear with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration.

Pic 42

(2) Using the crankshaft pulley bolt, turn the crankshaft to position the key on the crankshaft upward.

Pic 43

(b) Install the chain onto the crankshaft timing sprocket with the gold or orange mark link aligned with the timing mark on the crankshaft.

Pic 44

(c) Using SST and a hammer, tap in the crankshaft timing sprocket.
SST: 09309-37010

pic 45

(d) Align the gold or yellow links with each timing mark located on the camshaft timing gear and sprocket, then install the chain.
5. INSTALL CHAIN TENSIONER SLIPPER

pic 46

(a) Install the chain tensioner slipper with the bolt.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
6. INSTALL TIMING CHAIN GUIDE

pic 47

(a) Install the timing chain guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
7. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

pic 48

(a) Install the sensor plate with the "F" mark facing forward.
8. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
(a) Remove any old packing material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.

Pic 49

(b) Apply seal packing (Diameter 4.0 to 4.5 mm (0.157 to 0.177 in.)) As shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
- Remove any oil from the contact surface.
- Install the chain cover within 3 minutes of applying seal packing.
- Do not add engine oil for at least 2 hours after installing the chain cover.
(c) Apply a continuous bead of seal packing as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE:
- Remove any oil from the contact surface.
- Install the chain cover within 3 minutes of applying seal packing.
- Do not add engine oil for at least 2 hours after installing the chain cover.

Pic 50

pic 51

(d) Install the timing chain cover with the 12 bolts and 2 nuts.
Torque Bolt A: 9.0 Nm (92 kgf-cm, 80 in-lbf)
Torque Bolt B: 25 Nm (255 kgf-cm, 18 ft-lbf)
Torque Bolt C: 55 Nm (561 kgf-cm, 41 ft-lbf)
Torque Nut: 11 Nm (112 kgf-cm, 8 ft-lbf)
HINT: Bolt length:

pic 52

pic 53

(e) Using an E10 "TORX" socket, install the stud bolt for the V-ribbed belt tensioner.
Torque: 21.5 Nm (219 kgf-cm, 16 ft-lbf)
9. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

pic 54

(a) Release the ratchet pawl, then fully push in the plunger and hook the hook to the pin so that the plunger is in the position shown in the illustration.

Pic 55

(b) Install a new gasket and the chain tensioner with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTE: When installing the chain tensioner, set the hook again if the hook releases the plunger.
10. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

pic 56

(a) Install the V-ribbed belt tensioner with the bolt and nut.
Torque: 59.5 Nm (607 kgf-cm, 44 ft-lbf)
NOTE: Do not lift the engine more than necessary.
11. INSTALL ENGINE MOUNTING BRACKET RH

pic 57

(a) Install the engine mounting bracket RH with the 3 bolts.
Torque: 55 Nm (561 kgf-cm, 41 ft-lbf)
12. INSTALL CRANKSHAFT PULLEY

pic 58

(a) Using SST, fix the pulley in place and tighten the bolt.
SST: 09213-54015
91651-60855
SST: 09330-00021
Torque: 180 Nm (1,835 kgf-cm, 133 ft-lbf)

pic 59

(b) Turn the crankshaft counterclockwise, then disconnect the plunger knock pin from the hook.

Pic 60

(c) Turn the crankshaft clockwise, then check that the plunger is extended.
13. INSTALL OIL PAN SUB-ASSEMBLY
(a) Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.

Pic 61

(b) Apply a continuous bead of seal packing (Diameter 3.0 to 4.0 mm (0.118 to 0.157 in.)) As shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
- Remove any oil from the contact surface.
- Install the oil pan within 3 minutes of applying seal packing.
- Do not add engine oil for at least 2 hours after installing the oil pan.
(c) Install the oil pan to the cylinder block.

Pic 62

(d) Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)

pic 63

(e) Place a transmission jack underneath the engine, then put a wooden block on the jack.
(f) Remove the chain block and sling device.
(g) Remove the No. 1 and No. 2 engine hangers.
14. INSTALL CRANKSHAFT POSITION SENSOR See: Crankshaft Position Sensor > Removal and Replacement > Installation
15. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Remove any old packing material from the contact surface.

Pic 64

(b) Apply seal packing to the 2 locations shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
- Remove any oil from the contact surface.
- Install the oil pan within 3 minutes of applying seal packing.
- Do not add engine oil for at least 2 hours after installing the oil pan.

Pic 65

(c) Install the cylinder head cover with the 8 bolts and 2 nuts.
Torque Bolt A: 11 Nm (112 kgf-cm, 8 ft-lbf)
Torque Bolt B: 14 Nm (143 kgf-cm, 10 ft-lbf)
Torque Nut: 11 Nm (112 kgf-cm, 8 ft-lbf)

pic 66

(d) Install the 2 engine wires with the 2 bolts.
Torque: 8.4 Nm (86 kgf-cm, 74 in-lbf)

pic 67

(e) Connect the 2 ventilation hoses to the cylinder head cover.
16. INSTALL SPARK PLUG See: Valve Clearance > Adjustments > Adjustment
17. INSTALL IGNITION COIL ASSEMBLY See: Ignition Coil > Removal and Replacement > Installation
18. INSTALL IDLER PULLEY

pic 68

(a) Install the idler pulley with the 2 bolts.
Torque: 60 Nm (612 kgf-cm, 44 ft-lbf)
19. INSTALL ENGINE MOUNTING INSULATOR RH

pic 69

(a) Install the engine mounting insulator RH with the 4 bolts and 2 nuts.
Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)
Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)
Torque: 52 Nm (530 kgf-cm, 38 ft-lbf)

pic 70

(b) Connect the 2 clamps of the engine wire.
(c) Install the wire harness protector with the bolt.
20. INSTALL ENGINE MOUNTING INSULATOR FR

pic 71

(a) Install the engine mounting insulator FR with the 2 bolts.
Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)

pic 72

(b) Install the through bolt and nut.
Torque: 145 Nm (1,479 kgf-cm, 107 ft-lbf)
HINT: Install the bolt which is used to secure the front engine mounting bracket FR.
21. INSTALL RADIATOR RESERVOIR

pic 73

(a) Install the radiator reservoir with the 2 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
22. INSTALL GENERATOR ASSEMBLY
23. INSTALL FAN AND GENERATOR V BELT See: Drive Belt > Removal and Replacement > Installation
24. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH See: Drive Belt > Removal and Replacement > Installation
25. INSTALL FRONT EXHAUST PIPE See: Exhaust Pipe > Removal and Replacement > Installation
26. ADD ENGINE OIL See: Engine Oil > Removal and Replacement > Replacement
27. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
28. INSPECT FOR ENGINE OIL LEAK
29. INSPECT FOR EXHAUST GAS LEAK
30. INSTALL NO. 1 ENGINE COVER

(a) Install the engine cover with the 2 nuts.
Torque: 7.0 Nm (71 kgf-cm, 62 in-lbf)
31. INSTALL FRONT FENDER APRON RH
32. INSTALL NO. 1 ENGINE UNDER COVER
33. INSTALL FRONT WHEEL RH
34. INSTALL RADIATOR SUPPORT OPENING COVER

________________________

I hope this helps. Let me know.

Take care,
Joe
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Tuesday, December 29th, 2020 AT 10:20 PM
Tiny
PAPPA_SMURF
  • MEMBER
Hi,

Thanks a million.
I note the differences in the motors, but, it does help me with the basic procedures.
Thank you very much for the effort to help, it is really appreciated.
Will get under and do my best. Must just be careful with the TDC.
Have a safe and prosperous new year.
Best Regards.
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Thursday, December 31st, 2020 AT 12:52 AM
Tiny
JACOBANDNICKOLAS
  • EXPERT
Hi,

You are very welcome. Do me a favor. Many engines are interference engines. That means there isn't enough room between an open valve and the top of the piston if the timing is wrong. In the event the timing is off, this is an interference engine, and you try to start it, internal damage can occur.

With that in mind, before you try starting it do this. Once you have the timing set and the chains are installed, turn the engine several revolutions by hand to confirm there is nothing hitting internally. The best way to do this is with the spark plugs removed. That way if there is resistance, it won't be from compression and it will be easier to recognize.

If when turning it stops, don't force it. Recheck timing.

Please feel free to let me know if I can help.

Take care and Happy New Year!

Joe
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Thursday, December 31st, 2020 AT 10:02 AM
Tiny
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  • MEMBER
Great stuff.
Thank you very much for the help, you've been great.
Have a good and safe new year. Will definitely contact if I have problems.
Best Regards.
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Friday, January 1st, 2021 AT 10:49 PM
Tiny
JACOBANDNICKOLAS
  • EXPERT
You are very welcome, and I wish you a good new year as well. Please feel free to come back anytime in the future. You're always welcome.

Joe
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Saturday, January 2nd, 2021 AT 12:05 AM

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