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Home >> Toyota Truck >> 2005 >> Tacoma PreRunner L4-2.7L (2TR-FE) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Timing Components >> Timing Chain >> Service and Repair >> Part 2

Part 2

Replacement Continued





60. INSTALL CHAIN TENSIONER ASSEMBLY NO.2
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.





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





62. 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.





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





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





65. 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.





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





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





68. 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.)





70. INSTALL OIL PAN SUB-ASSEMBLY
a. Apply continuous beads of seal packing to the places shown in the illustration.
Seal packing: Part No.08826-00080 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.)





71. 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.)





72. INSTALL OIL PAN SUB-ASSEMBLY NO.2
a. Apply continuous beads of seal packing to the places shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent
Seal width: 3 to 4 mm (0.118 to O.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.
73. INSTALL OIL LEVEL GAGE SUB-ASSEMBLY
74. INSTALL CRANKSHAFT PULLEY SST 09213-54015 (91651-60855), 09330-00021
75. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
76. INSTALL INTAKE MANIFOLD TO HEAD GASKET NO.1
77. INSTALL CAMSHAFT POSITION SENSOR
78. INSTALL CRANKSHAFT POSITION SENSOR
79. INSTALL IDLE PULLEY ASSEMBLY W/BRACKET (W/ AIR CONDITIONING)





80. INSTALL IDLER PULLEY SUB-ASSEMBLY NO.1
a. Install the idler pulley sub-assembly No.1 with the bolt.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
81. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
82. INSTALL GENERATOR ASSEMBLY
83. INSTALL INTAKE AIR CONNECTOR
84. INSTALL REAR END PLATE
a. Install the rear end plate with the 2 bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
85. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY (AUTOMATIC TRANSMISSION)
SST 09213-54015 (91651-60855), 09330-00021
86. INSTALL FLYWHEEL SUB-ASSEMBLY (MANUAL TRANSMISSION)
SST 09213-54015 (91651-60855), 09330-00021
87. INSTALL CLUTCH DISC ASSEMBLY (MANUAL TRANSMISSION)
88. INSTALL CLUTCH COVER ASSEMBLY (MANUAL TRANSMISSION)
89. INSTALL ENGINE ASSEMBLY
90. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
91. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY
92. INSTALL EXHAUST PIPE ASSEMBLY FRONT
93. INSTALL EXHAUST PIPE ASSEMBLY TAIL
94. CONNECT ENGINE WIRE
95. CONNECT AIR INJECTION SYSTEM NO.1 HOSE
96. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY
97. CONNECT FUEL HOSE NO.2
98. CONNECT FUEL HOSE
99. INSTALL WATER HOSE SUB-ASSEMBLY
100. INSTALL RADIATOR HOSE INLET





101. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
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.)
102. INSTALL RADIATOR HOSE NO.2





103. 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.
104. INSTALL AIR CLEANER CASE
a. Install the air cleaner case with the 3 bolts.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
105. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
106. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
107. INSTALL FAN SHROUD
108. INSTALL RADIATOR SUPPORT TO FRAME SEAL LH
109. INSTALL BATTERY TRAY
110. INSTALL BATTERY
111. ADD ENGINE OIL
112. ADD ENGINE COOLANT
113. CHECK ENGINE OIL LEVEL
114. CHECK FOR FUEL LEAKAGE
115. CHECK FOR ENGINE COOLANT LEAKAGE
116. CHECK FOR OIL LEAKAGE
117. CHECK FOR EXHAUST GAS LEAKAGE
118. ENGINE UNDER COVER SUB-ASSEMBLY NO.1 (PRE RUNNER AND 4WD TYPE)
a. Install the engine under cover No.1 with the 4 bolts.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
119. ENGINE UNDER COVER SUB-ASSEMBLY NO.2 (PRE RUNNER AND 4WD TYPE, REGULAR CAB)
a. Install the engine under cover No.2 with the 4 bolts.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
120. INSTALL HOOD SUB-ASSEMBLY
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