Timing Chain: Service and Repair

TIMING CHAIN

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

COMPONENTS (Part 8):

COMPONENTS (Part 9):

COMPONENTS (Part 10):

COMPONENTS (Part 11):

COMPONENTS (Part 12):

COMPONENTS (Part 13):

COMPONENTS (Part 14):

REMOVAL
1. REMOVE HOOD SUB-ASSEMBLY
2. DISCHARGE FUEL SYSTEM PRESSURE
3. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (for 4WD and Pre-Runner)
(a) Remove the 4 bolts, then remove the No. 1 engine under cover.
4. REMOVE NO. 2 ENGINE UNDER COVER SUB-ASSEMBLY (for 4WD and Pre-Runner, Regular Cab)
(a) Remove the 4 bolts, then remove the No. 2 engine under cover.
5. DRAIN ENGINE OIL
6. DRAIN ENGINE COOLANT
7. REMOVE BATTERY
8. REMOVE BATTERY TRAY
9. REMOVE RADIATOR SUPPORT TO FRAME SEAL LH
10. REMOVE FAN SHROUD
11. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
12. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
13. REMOVE AIR CLEANER CASE
(a) Remove the 3 bolts, then remove the air cleaner case.

14. SEPARATE VANE PUMP ASSEMBLY
(a) Disconnect the vane pump connector.
(b) Remove the 2 bolts, then separate the vane pump.

HINT: Do not disconnect the hose. Hang the vane pump with a rope.

15. REMOVE NO. 2 RADIATOR HOSE

16. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)
(a) Remove the bolt shown in the illustration.

(b) Disconnect the compressor and magnetic clutch connector.
(c) Remove the 4 bolts, then separate the compressor and magnetic clutch.

HINT: Do not disconnect the hose. Hang the vane pump with a rope.

17. REMOVE RADIATOR HOSE INLET
18. SEPARATE WATER HOSE SUB-ASSEMBLY
19. DISCONNECT FUEL HOSE
20. DISCONNECT FUEL HOSE NO.2
21. SEPARATE FUEL VAPOR FEED HOSE ASSEMBLY
22. DISCONNECT NO. 1 AIR INJECTION HOSE
23. DISCONNECT ENGINE WIRE
24. REMOVE EXHAUST PIPE ASSEMBLY
25. REMOVE FRONT EXHAUST PIPE ASSEMBLY
26. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY
27. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY
28. REMOVE ENGINE ASSEMBLY )
29. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)
30. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission)
31. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)
32. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)
33. REMOVE REAR END PLATE
(a) Remove the 2 bolts, then remove the rear end plate.
34. REMOVE INTAKE AIR CONNECTOR
35. REMOVE GENERATOR ASSEMBLY
36. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

37. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY
(a) Remove the bolt and No. 1 idler pulley sub-assembly.
38. REMOVE IDLE PULLEY ASSEMBLY WITH BRACKET (w/ Air Conditioning System)
39. REMOVE CRANKSHAFT POSITION SENSOR
40. REMOVE CAMSHAFT POSITION SENSOR
41. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET
42. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

43. REMOVE CRANKSHAFT PULLEY
(a) Set the No. 1 cylinder to the TDC/ compression.
(1) Turn the crankshaft pulley clockwise and align its timing mark notch with the timing mark "0".
(2) Check that the timing marks of the camshaft timing gear are located as illustrated.

HINT: If not, turn the crankshaft to align the marks.

(b) Using SST, loosen the crankshaft pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021

HINT: Loosen the crankshaft pulley bolt until only 2 or 3 threads are still installed in the crankshaft.

(c) Using SST, remove the crankshaft pulley and crankshaft pulley bolt.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09954-05021)
44. REMOVE OIL LEVEL GAGE SUB-ASSEMBLY

45. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY
(a) Remove the 18 bolts and 2 nuts.

(b) Insert the blade of SST between the pans. Cut through the applied sealer and remove the oil pan.
SST 09032-00100

NOTICE: Be careful not to damage the contact surface of the oil pans.

46. REMOVE OIL STRAINER SUB-ASSEMBLY
(a) Remove the 2 bolts, 2 nuts, oil strainer and gasket.

47. REMOVE OIL PAN SUB-ASSEMBLY
(a) Remove the 16 bolts and 2 nuts.

(b) Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver.

HINT: Tape the screwdriver tip before use.

NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pan.

48. REMOVE TIMING CHAIN COVER

49. REMOVE TIMING CHAIN GUIDE
(a) Make sure that each matchmark is in the position shown in the illustration.

(b) Remove the 2 bolts, timing chain guide and O-ring.

50. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

NOTICE:
^ When the chain tensioner is removed, do not rotate the crankshaft.
^ When the chain is removed and the camshaft needs to be rotated, rotate the crankshaft 90° to the right.

(a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
(b) Move the stopper plate downward to set the lock, and insert a 3.0 mm (0.118 inch) diameter bar into the stopper plate hole.

51. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the bolt and tensioner slipper.

52. REMOVE NO. 1 CHAIN VIBRATION DAMPER
(a) Remove the 2 bolts and vibration damper.
53. REMOVE CHAIN SUB-ASSEMBLY

54. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
(a) Remove the crankshaft timing gear from the crankshaft.

55. REMOVE NO. 2 CHAIN VIBRATION DAMPER
(a) Remove the bolt and No. 2chain vibration damper.

56. REMOVE NO. 3 CHAIN VIBRATION DAMPER
(a) Remove the 2 bolts and No. 3chain vibration damper.

57. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Remove the nut and No. 2 chain tensioner assembly.

58. REMOVE NO.2 CHAIN SUB-ASSEMBLY
(a) Remove the bolt, balance shaft drive gear shaft and balance shaft drive gear.
(b) Remove the crankshaft timing sprocket No. 2 and chain.

INSTALLATION

1. INSTALL NO.2 CHAIN SUB-ASSEMBLY
(a) Install the chain with its mark links aligned with the timing marks on the crankshaft timing sprocket and balance shaft timing sprocket.

(b) Bring the other mark link of the crankshaft timing sprocket behind the large timing mark of the balance shaft drive gear.
(c) Insert the balance shaft drive gear shaft through the balance shaft drive gear so that it fits into the thrust plate hole.

(d) Align the small timing mark of the balance shaft drive gear with the timing mark of the balance shaft timing gear.
(e) Install the bolt onto the balance shaft drive gear and tighten it.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)

(f) Check that each timing mark is aligned with the corresponding mark link.

2. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Install the chain tensioner with the nut.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)

NOTICE: Assemble the chain tensioner with the 3.0 mm (0.118 inch) diameter bar installed, then remove the bar after assembly. When doing this, avoid pushing the vibration damper against the chain.

3. INSTALL NO. 3 CHAIN VIBRATION DAMPER
(a) Install the No. 3 chain vibration damper with the 2 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)

4. INSTALL CHAIN VIBRATION DAMPER NO.2
(a) Install the chain vibration damper with the bolt.
Torque: 27 Nm (270 kgf-cm, 20 ft. lbs.)
(b) Remove the pin from the chain tensioner and release the plunger.

5. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
(a) Install the timing sprocket as shown in the illustration.

6. INSTALL NO. 1 CHAIN VIBRATION DAMPER
(a) Install the vibration damper with the bolt and nut.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)

7. INSTALL CHAIN SUB-ASSEMBLY
(a) As shown in the illustration, install the chain onto the sprocket and gear with the painted marks aligned with the timing marks on the sprocket and gear.

HINT:
^ The camshaft mark plate is orange.
^ The crankshaft mark plate is yellow.

(b) Use a rope to tie the chain of the crankshaft timing sprocket. Tie the rope near the sprocket.

NOTICE: After the chain tensioner has been installed, the rope must be removed.

HINT: The rope is tied to prevent gear jumping.

8. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the tensioner slipper with the bolt.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)

9. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
(a) Install a new gasket and the chain tensioner with the bolt and nut.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)

10. INSTALL TIMING CHAIN GUIDE
(a) Install a new O-ring and the chain guide with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
11. INSTALL TIMING CHAIN COVER

12. INSTALL OIL PAN SUB-ASSEMBLY
(a) Apply continuous beads of seal packing to the places shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal width: 2 to 3 mm (0.079 to 0.118 inch)

NOTICE:
^ Remove any oil from the contact surface.
^ Install the crankcase within 3 minutes of applying the seal packing.
^ Do not start the engine for at least 2 hours after installation.

(b) Loosely install the oil pan with the 16 bolts and 2 nuts.

HINT:
Bolt length:
20 mm (0.79 inch) for bolt A,
40 mm (1.57 inch) for bolt B

(c) Uniformly tighten the 16 bolts and 2 nuts in the sequence shown in the illustration.
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)

13. INSTALL OIL STRAINER SUB-ASSEMBLY
(a) Install a new gasket and the oil strainer with the 2 bolts and 2 nuts.
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)

14. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
(a) Apply continuous beads of seal packing to the places shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal width: 3 to 4 mm (0.118 to 0.157 inch)

NOTICE:
^ Remove any oil from the contact surface.
^ Install the crankcase within 3 minutes of applying the seal packing.
^ Do not start the engine for at least 2 hours after installation.

(b) Provisionally install the oil pan with the 18 bolts and 2 nuts.
(c) Uniformly tighten the 18 bolts and 2 nuts in the sequence shown in the illustration.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
(d) Install a new gasket and the drain plug.
15. INSTALL OIL LEVEL GAGE SUB-ASSEMBLY
16. INSTALL CRANKSHAFT PULLEY
17. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
18. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET
19. INSTALL CAMSHAFT POSITION SENSOR
20. INSTALL CRANKSHAFT POSITION SENSOR
21. INSTALL IDLE PULLEY ASSEMBLY WITH BRACKET (w/ Air Conditioning System)

22. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY
(a) Install the No. 1 idler pulley sub-assembly with the bolt.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
23. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
24. INSTALL GENERATOR ASSEMBLY
25. INSTALL INTAKE AIR CONNECTOR
26. INSTALL REAR END PLATE
(a) Install the rear end plate with the 2 bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
27. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)
28. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)
29. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission)
30. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission)
31. INSTALL ENGINE ASSEMBLY
32. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
33. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY
34. INSTALL EXHAUST PIPE ASSEMBLY FRONT
35. INSTALL EXHAUST PIPE ASSEMBLY TAIL
36. CONNECT ENGINE WIRE
37. CONNECT NO. 1 AIR INJECTION HOSE
38. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY
39. CONNECT NO. 2 FUEL HOSE
40. CONNECT FUEL HOSE
41. INSTALL WATER HOSE SUB-ASSEMBLY
42. INSTALL RADIATOR HOSE INLET

43. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)
(a) Install the compressor and magnetic clutch with the 4 bolts.
Torque: 21 Nm (214 kgf-cm, 16 ft. lbs.)
(b) Connect the compressor and magnetic clutch connector.

(c) Install the bolt shown in the illustration.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
44. INSTALL NO. 2 RADIATOR HOSE

45. INSTALL VANE PUMP ASSEMBLY
(a) Install the vane pump with the 2 bolts.
Torque: 21 Nm (214 kgf-cm, 16 ft. lbs.)
(b) Connect the vane pump connector.
46. INSTALL AIR CLEANER CASE
(a) Install the air cleaner case with the 3 bolts.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
47. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
48. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
49. INSTALL FAN SHROUD
50. INSTALL RADIATOR SUPPORT TO FRAME SEAL LH
51. INSTALL BATTERY TRAY
52. INSTALL BATTERY
53. ADD ENGINE OIL
54. ADD ENGINE COOLANT
55. CHECK FOR ENGINE OIL LEVEL
56. CHECK FOR FUEL LEAKAGE
57. CHECK FOR ENGINE COOLANT LEAKAGE
58. CHECK FOR OIL LEAKAGE
59. CHECK FOR EXHAUST GAS LEAKAGE
60. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (for 4WD and Pre-Runner)
(a) Install the No. 1 engine under cover with the 4 bolts.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
61. INSTALL NO. 2 ENGINE UNDER COVER SUB-ASSEMBLY (for 4WD and Pre-Runner, Regular Cab)
(a) Install the No. 2 engine under cover with the 4 bolts.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
62. INSTALL HOOD SUB-ASSEMBLY