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Home >> Toyota Truck >> 2005 >> Tacoma 2WD V6-4.0L (1GR-FE) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Timing Components >> Timing Chain >> Service and Repair >> Part 1

Part 1

CHAIN SUB-ASSEMBLY (1GR-FE(2WD))
































COMPONENTS

REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE
2. REMOVE BATTERY
3. DRAIN ENGINE COOLANT
4. DRAIN ENGINE OIL
5. REMOVE ENGINE ASSEMBLY
6. REMOVE OIL LEVEL GAUGE 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.
7. REMOVE WATER INLET
8. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
9. REMOVE IDLER PULLEY SUB-ASSEMBLY NO.2
a. Remove the 2 bolts, then remove the idler pulley No.2.
10. REMOVE IDLER PULLEY SUB-ASSEMBLY NO.1
a. Remove the bolt, then remove the idler pulley No.1.
11. REMOVE CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05030)





12. REMOVE OIL PAN SUB-ASSEMBLY NO.2
a. Remove the 15 bolts and 2 nuts.





b. Insert the blade of SST between the oil pan and oil pan No.2, cut off applied sealer and remove the oil pan No.2.
SST 09032-00100

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





13. REMOVE OIL STRAINER SUB-ASSEMBLY
a. Remove the 2 nuts, then remove the oil strainer and gasket.





14. REMOVE OIL PAN SUB-ASSEMBLY
a. Remove the 17 bolts and 2 nuts.





b. 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.

15. REMOVE INTAKE AIR SURGE TANK
16. REMOVE IGNITION COIL ASSEMBLY
17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
19. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
20. REMOVE WT SENSOR
21. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
22. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL





23. SET NO.1 CYLINDER 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.
24. REMOVE CHAIN TENSIONER ASSEMBLY NO.1

NOTICE:
- Never rotate the crankshaft with the chain tensioner removed.
- When rotating the camshaft with the timing chain re moved, 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 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.
25. REMOVE CHAIN TENSIONER SLIPPER





26. 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.
27. REMOVE CHAIN VIBRATION DAMPER NO.2
a. Remove the 2 chain vibration dampers No.2.
28. REMOVE CHAIN SUB-ASSEMBLY
29. INSTALL CHAIN TENSIONER SLIPPER





30. INSTALL CHAIN TENSIONER ASSEMBLY NO.1
a. While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration.
b. While turning the stopper plate of the tensioner counterclockwise, insert a bar of 35 mm (0.138 inch) into the holes in the stopper plate and tensioner to fix the stopper plate.
c. Install the chain tensioner with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7.4 ft. lbs.)
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