TOYOTA Aygo 1.

0 VVT-i 1KR-FE

Timing chain: removal/installation

General
The instruction manual is for removed engine

Removal
Disconnect the battery earth cable
Drain the engine oil
Drain the gearbox oil
Drain the cooling system
Remove the ancillary drive belt
Remove the oil sump
Remove both front drive shafts
Remove the engine together with the gearbox
Remove the alternator
Remove the dipstick tube

Remove the dipstick O-ring

Disconnect the camshaft position sensor(s)
Remove the crankshaft position sensor
Timing chain: removal/installation
General
The instruction manual is for removed engine

Removal
Disconnect the battery earth cable
Drain the engine oil
Drain the gearbox oil
Remove
Drain thethe valvesystem
cooling cover
Remove the oil filter housing
ancillary drive belt
Remove the oil sump
Remove both front drive shafts
Remove the engine together with the gearbox
Remove the alternator
Remove the dipstick tube

Remove the coolant pump

Remove the dipstick O-ring

Disconnect the camshaft position sensor(s)
Remove the crankshaft position sensor

Turn the crankshaft clockwise

Align the crankshaft timing marks
Timing chain: removal/installation
General
The instruction manual is for removed engine

Removal
Disconnect the battery earth cable
Drain the engine oil
Drain the gearbox oil
Drain the cooling system
Remove the ancillary drive belt
Remove the camshaft cover
Remove the oil sump
Check the camshaft timing marks
Remove both front drive shafts
Remove the engine together with the gearbox
Remove the alternator
Remove the dipstick tube

If necessary
Turn the crankshaft by 1 turn
Use the special
Remove tools to
the dipstick remove the crankshaft pulley
O-ring (0132.AA)
Remove thethe
Disconnect timing chainposition
camshaft cover sensor(s)
Lock the the
Remove tensioner; use position
crankshaft a lockingsensor
pin
Remove the chain tensioner
Remove the chain tensioner rail(s)
Remove the timing chain
Remove the crankshaft gearwheel
Remove the woodruff key
Timing chain: removal/installation
General
Installation
The instruction
Refit the woodruff
manual
key is for removed engine

Removal
Refit the crankshaft gearwheel
Disconnect
Align the yellow
the battery
plate on
earth
the cable
timing chain with the mark on the crankshaft gearwheel
Drain the engine oil
Drain the gearbox oil
Drain the cooling system
Remove the ancillary drive belt
Remove the oil sump
Remove both front drive shafts
Remove the engine together with the gearbox
Remove
Align thethe alternator
orange plate(s) on the timing chain with the mark on the camshaft(s) gearwheel
Remove the dipstick tube

Turn the camshaft slightly anti-clockwise to slacken the chain at the tensioner side

Remove the dipstick O-ring

Disconnect the camshaft position sensor(s)
Remove the crankshaft position sensor
Timing chain: removal/installation
General
Fit the chain tensioner
The instruction manual is for removed engine

Removal
Disconnect the battery earth cable
Drain the engine oil
Drain the gearbox oil
Drain the cooling system
Remove the ancillary drive belt
Remove the oil sump
Remove both front drive shafts
Remove the
Compress theengine
tensioner
together with the gearbox
Remove the alternator
tensioner locking pin
Remove
Turn the the
crankshaft
dipstick clockwise
tube 2 rotations
Release the tensioner pressure
Check the camshaft timing marks

Remove the dipstick O-ring

Disconnect the camshaft position sensor(s)
Remove the crankshaft position sensor

Camshaft cover:
Check and renew if necessary
Refit the camshaft cover
Fit the crankshaft oil seal
Use the special tool (0196.B)
Timing chain: removal/installation
General
Clean off the sealing surfaces
The instruction
Refit the timing manual
chain cover
is for removed engine

Removal
Note: Apply sealant before fitting
Disconnect
Tighten the the
bolts
battery
in a criss-cross
earth cablepattern, starting from the centre
Drain
Bolts:
the engine
(A:oil
24 Nm)
Drain
Bolts:
the gearbox
(B: 40
oil Nm)
Drain
Bolts:
the cooling
(C: system
15 Nm)
Remove the ancillary drive belt
Remove the oil sump
Remove both front drive shafts
Remove the engine together with the gearbox
Remove the alternator
Remove the dipstick tube

Remove/clean off any excess sealant

Coolant pump:
Renew
Removethe
thegasket
dipstick O-ring
Refit the coolant
Disconnect pump position
the camshaft (28 Nm)
sensor(s)
Use the special
Remove tools to refit
the crankshaft the crankshaft
position sensor pulley (170 Nm)
Refit the oil filter housing (20 - 30 Nm)
Refit the valve cover (8 Nm)
Refit the crankshaft position sensor (7 Nm)
Reconnect the crankshaft position sensor
Refit the dipstick O-ring
Timing chain: removal/installation
General before fitting
Lubricate
The instruction
Refit the dipstickmanual
tube is for removed engine

Removal
Refit the alternator (54 Nm)
Disconnect
Refit the engine
the battery
together
earth
withcable
the gearbox
Drainthe
Refit thefront
engine
drive
oil shafts
Drain the
Refit the engine
gearbox
lower
oil cover
Drainthe
Refit theancillary
cooling system
drive belt
Remove
Refill the the
engine
ancillary
oil drive belt
Remove
Refill thethe
gearbox
oil sump
oil
Remove
Refill the both
cooling
front
system
drive shafts
Remove thethe
Reconnect engine
battery
together
earth cable
with the gearbox

Torque settings
Remove the alternator
Remove the dipstick tube
Alternator
Crankshaft pulley
Coolant pump
Valve cover
Crankshaft position sensor (7 Nm)
Timing chain lower cover
Bolts: (A: 24 Nm)
Bolts: (B: 40 Nm)
Remove the dipstick O-ring
Bolts: (C: 15 Nm)
Disconnect the camshaft position sensor(s)
Remove the crankshaft position sensor
Timing chain: removal/installation
General
The instruction manual is for removed engine

Removal
Disconnect the battery earth cable
Drain the engine oil
Drain the gearbox oil
Drain the cooling system
Remove the ancillary drive belt
Remove the oil sump
Remove both front drive shafts
Remove the engine together with the gearbox
©HaynesPro B.V.
Remove the alternator
Remove the dipstick tube