Removal

2TR-FE ENGINE MECHANICAL: TIMING CHAIN:

REMOVAL

1. REMOVE HOOD SUB-ASSEMBLY
2. DISCHARGE FUEL SYSTEM PRESSURE (Technician Safety Information)

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 (Removal)

6. DRAIN ENGINE COOLANT (Service and Repair)

7. REMOVE BATTERY
8. REMOVE BATTERY TRAY
9. REMOVE RADIATOR SUPPORT TO FRAME SEAL LH (Removal)

10. REMOVE FAN SHROUD (Removal)

11. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (Removal)

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 (Removal)

19. DISCONNECT FUEL HOSE (Removal)

20. DISCONNECT FUEL HOSE NO.2 (Removal)

21. SEPARATE FUEL VAPOR FEED HOSE ASSEMBLY (Removal)

22. DISCONNECT NO. 1 AIR INJECTION HOSE (Removal)

23. DISCONNECT ENGINE WIRE (Removal)

24. REMOVE EXHAUST PIPE ASSEMBLY (Removal)

25. REMOVE FRONT EXHAUST PIPE ASSEMBLY (Removal)

26. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY

27. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY

28. REMOVE ENGINE ASSEMBLY (Removal)

29. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)

30. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission)

31. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transmission) (Removal)

32. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission) (Removal)

33. REMOVE REAR END PLATE
(a) Remove the 2 bolts, then remove the rear end plate.
34. REMOVE INTAKE AIR CONNECTOR (Removal)

35. REMOVE GENERATOR ASSEMBLY (Service and Repair)

36. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (Removal)

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) (Removal)

39. REMOVE CRANKSHAFT POSITION SENSOR (Removal)

40. REMOVE CAMSHAFT POSITION SENSOR (Removal)

41. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET (Installation)

42. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (Removal)

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
SST: 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 oil pan seal cutter between the pans. Cut through the applied sealer and remove the oil pan.

NOTE: 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.

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

48. REMOVE TIMING CHAIN COVER (Removal)

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 in.) 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, balanceshaft drive gear shaft and balanceshaft drive gear.
(b) Remove the crankshaft timing sprocket No. 2 and chain.