Part 1
CHAIN (2TR-FE)
COMPONENTS
REPLACEMENT
1. REMOVE HOOD SUB-ASSEMBLY
2. DISCHARGE FUEL SYSTEM PRESSURE
3. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY NO.1 (PRE RUNNER AND 4WD TYPE)
a. Remove the 4 bolts, then remove the engine under cover No.1.
4. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY NO.2 (PRE RUNNER AND 4WD TYPE, REGULAR CAB)
a. Remove the 4 bolts, then remove the engine under cover No.2.
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 RADIATOR HOSE NO.2
16. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
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 AIR INJECTION SYSTEM NO.1 HOSE
23. DISCONNECT ENGINE WIRE
24. REMOVE EXHAUST PIPE ASSEMBLY TAIL
25. REMOVE EXHAUST PIPE ASSEMBLY FRONT
26. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY
27. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY
28. REMOVE ENGINE ASSEMBLY
29. REMOVE CLUTCH COVER ASSEMBLY (MANUAL TRANSMISSION)
30. REMOVE CLUTCH DISC ASSEMBLY (MANUAL TRANSMISSION)
31. REMOVE FLYWHEEL SUB-ASSEMBLY (MANUAL TRANSMISSION)
SST 09213-54015 (91651-60855), 09330-00021
32. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY (AUTOMATIC TRANSMISSION)
SST 09213-54015 (91651-60855), 09330-00021
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 IDLER PULLEY SUB-ASSEMBLY NO.1
a. Remove the bolt and idler pulley sub-assembly No.1.
38. REMOVE IDLE PULLEY ASSEMBLY W/BRACKET (W/ AIR CONDITIONING)
39. REMOVE CRANKSHAFT POSITION SENSOR
40. REMOVE CAMSHAFT POSITION SENSOR
41. REMOVE INTAKE MANIFOLD TO HEAD GASKET NO.1
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 OIL PAN SUB-ASSEMBLY NO.2
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 CHAIN TENSIONER ASSEMBLY NO.1
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.
c. Remove the bolt, nut, chain tensioner and gasket.
51. REMOVE CHAIN TENSIONER SLIPPER
a. Remove the bolt and tensioner slipper.
52. REMOVE CHAIN VIBRATION DAMPER NO.1
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 CHAIN VIBRATION DAMPER NO.2
a. Remove the bolt and chain vibration damper No.2.
56. REMOVE CHAIN VIBRATION DAMPER NO.3
a. Remove the 2 bolts and chain vibration damper No.3.
57. REMOVE CHAIN TENSIONER ASSEMBLY NO.2
a. Remove the nut and chain tensioner assembly No.2.
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.
59. 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.