Removal

1GR-FE ENGINE MECHANICAL: TIMING CHAIN (for 4WD and Pre-Runner): REMOVAL

REMOVAL

1. REMOVE BATTERY
2. DRAIN ENGINE COOLANT Service and Repair
3. DRAIN ENGINE OIL Installation
4. REMOVE POWER STEERING LINK ASSEMBLY Removal
5. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD)
6. REMOVE V-BANK COVER Removal
7. REMOVE RADIATOR SUPPORT TO FRAME SEAL LH Removal
8. REMOVE FAN SHROUD Removal
9. REMOVE AIR CLEANER ASSEMBLY Removal
10. REMOVE OIL LEVEL GAGE GUIDE
(a) Remove the oil level gauge.
(b) Remove the bolt and pull out the oil level gauge guide.
(c) Remove the O-ring from the oil level gauge guide.
11. REMOVE WATER INLET Removal

12. SEPARATE VANE PUMP ASSEMBLY
(a) Disconnect the power steering pressure switch connector.
(b) Remove the 2 bolts, then separate the vane pump.
NOTICE: Do not hit the pulley with other parts when separating the vane pump.
HINT: The vane pump is suspended securely.

13. REMOVE GENERATOR ASSEMBLY Removal
14. SEPARATE COOLER COMPRESSOR ASSEMBLY Removal

15. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(a) Remove the 5 bolts, then remove the V-ribbed belt tensioner.
16. REMOVE NO.2 IDLER PULLEY SUB-ASSEMBLY
(a) Remove the 2 bolts, then remove the idler pulley No. 2.
17. REMOVE NO.1 IDLER PULLEY SUB-ASSEMBLY
(a) Remove the bolt, then remove the idler pulley No. 1.
18. REMOVE CRANKSHAFT PULLEY

(a) Using SST, hold the crankshaft pulley and loosen the pulley set bolt.
SST: 09213-54015
91651-60855
SST: 09330-00021

(b) Using the pulley set bolt and SST, remove the crankshaft pulley.
SST: 09950-50013
09951-05010
09952-05010
09953-05020
09954-05031
19. REMOVE NO.2 OIL PAN SUB-ASSEMBLY

(a) Remove the 10 bolts and 2 nuts.

(b) Insert the blade of the oil pan seal cutter between the oil pan and oil pan No. 2, cut off applied sealer and remove the oil pan No. 2.

NOTE:
- Be careful not to damage the contact surfaces of the oil pan and oil pan No. 2.
- Be careful not to damage the oil pan No. 2 flange.

20. REMOVE OIL STRAINER SUB-ASSEMBLY
(a) Remove the 2 nuts, then remove the oil strainer and gasket.
21. REMOVE OIL PAN SUB-ASSEMBLY

(a) Remove the 4 housing bolts.
(b) Remove the flywheel housing under cover.

(d) Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block.
NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pan.

(e) Remove the O-ring from the oil pump.
22. REMOVE INTAKE AIR SURGE TANK Removal
23. REMOVE IGNITION COIL ASSEMBLY Removal
24. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Removal
25. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH Removal
26. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Removal
27. REMOVE VVT SENSOR Removal
28. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY Removal
29. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Replacement
30. SET NO.1 COMPRESSION TO TDC/COMPRESSION

(a) Using the crankshaft pulley set bolt, turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block.

(b) Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration.
If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks as above.
31. REMOVE NO.1 CHAIN TENSIONER ASSEMBLY
NOTICE:
- Never rotate the crankshaft with the chain tensioner removed.
- When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first.

(a) While turning the stopper plate of the tensioner upward, push in the plunger of the chain tensioner as shown in the illustration.
(b) While turning the stopper plate of the tensioner down ward, insert a bar of dia 3.5 mm (0.138) into the holes in the stopper plate and tensioner to fix the stopper plate.
(c) Remove the 2 bolts, then remove the chain tensioner.
32. REMOVE CHAIN TENSIONER SLIPPER

33. REMOVE IDLE SPROCKET ASSEMBLY
(a) Using a 10 mm hexagon wrench, remove the idle gear shaft No. 2, idle gear No. 1 and idle gear shaft No. 1.
34. REMOVE NO.2 CHAIN VIBRATION DAMPER
(a) Remove the 2 chain vibration dampers No. 2.
35. REMOVE CHAIN SUB-ASSEMBLY