OEM 2004 Toyota Solara Timing Chain

2004 Toyota Solara Parts Questions & Experts Answers

• Q: How to replace the timing chain on 2004 Toyota Solara?

  A: A proper timing chain replacement begins with removing the hood sub-assembly and front right wheel as well as the engine under covers from both sides and the front fender apron seal on the right side. Prior to installation of a new gasket and drain plug you must drain the engine oil and torque it to 25 Nm (255 kgf-cm, 18 ft. lbs.). The exhaust pipe assembly and engine moving control rod with bracket together with engine mounting stay No.2 on the right along with engine mounting bracket No.2 on the right must be taken out. The service procedure involves removing the fan with generator V-belt then separating the engine cover sub-assembly No.1 before disconnecting the engine wire and extracting both the generator assembly and vane pump assembly without breaking the hose connection. The process begins by disconnecting the engine wire harness clamp then removing 8 bolts along with 2 nuts from the cylinder head cover sub-assembly combined with both ventilation hoses and ignition coil assembly. Set the No.1 cylinder to TDC compression position after which Special Service Tool: 09960-10010 (09962-01000, 09963-01000) is needed to fix the pulley before loosening the bolt and then extracting the pulley and bolt using Special Service Tool: 09950-40011 (09951-04010, 09952-04010, 09953-04030, 09954-04010, 09955-04041, 09957-04010, 91111-51014). Cut through the sealer separating the oil pan sub-assembly from the crankshaft position sensor using Special Service Tool: 09032-00100 by removing 12 bolts along with 2 nuts. Installation of the procedure requires first removing the chain tensioner assembly No.1 while avoiding crankshaft rotation without it followed by removal of the V-ribbed belt tensioner assembly. Use engine hangers No. 1 and No. 2 to install bolts after achieving 38 Nm (387 kgf-cm, 28 ft. lbs.) torque but extract the engine mounting insulator by suspending it from the hangers then disconnecting the FR side and removing the RH engine mounting bracket. Get the timing chain or belt cover sub-assembly by disassembling the drive belt tensioner stud bolt and 14 bolts along with 2 nuts and gently prying the cover from its position. The mechanic eliminates the crankshaft position sensor plate No.1 combined with chain tensioner slipper and chain vibration damper No.1 while also removing the chain sub-assembly followed by the crankshaft timing gear or sprocket. The crankshaft needs counterclockwise rotation by 90° to align the oil pump driven sprocket adjusting hole with the device's groove while using a 4 mm bar to lock the position before removing the nut plus bolt and chain tensioner plate with spring. The installation of the No.2 chain sub-assembly requires positioning the crankshaft key into the left horizontal position while directing the oil pump drive shaft cutout toward the top along with matching the mark links to the timing marks before inserting the sprockets with the chain. Install the chain tensioner plate after setting the nut on the oil pump driven sprocket then place the damper spring inside before tightening to 12 Nm (122 kgf-cm 9 ft. lbs.). Lock the adjusting hole of the oil pump driven sprocket to the groove by using a 4 mm bar before tightening the nut to 30 Nm torque (301 kgf-cm, 22 ft. lbs.). Turn the crankshaft 90 degrees counterclockwise until the crankshaft key reaches the top position. The installer should torque chain vibration damper No.1 to 9.0 Nm (92 kgf-cm, 80 inch lbs.) before aligning the camshaft timing gear/sprocket and bearing caps timing marks when the No. 1 cylinder is at TDC/compression. After tightening the chain tensioner slipper to 19 Nm (194 kgf-cm, 14 ft. lbs.), install the crankshaft position sensor plate No.1 by facing its F mark towards the front. To install the timing chain or belt cover sub-assembly use 14 bolts and 2 nuts while torquing to specified values after removing old packing and applying a continuous bead of seal packing (Part No. 08826-00080 or equivalent). The installation process requires V-ribbed belt tensioner assembly with engine mounting bracket RH and engine mounting insulator RH according to specified torque requirements. Finally, install the oil pan sub-assembly with seal packing, followed by the chain tensioner assembly No.1, crankshaft position sensor, crankshaft pulley using Special Service Tool: 09960-10010 (09962-01000, 09963-01000) with a torque of 170 Nm (1,733 kgf-cm, 125 ft. lbs.), and complete the assembly by reinstalling the cylinder head cover sub-assembly, ignition coil assembly, vane pump assembly, generator assembly, engine wire, fan and generator V-belt, engine mounting bracket No.2 RH, engine mounting stay No.2 RH, engine moving control rod with bracket, exhaust pipe assembly, front right wheel, and hood sub-assembly, ensuring to add engine oil and check for leaks.