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Replacement

TIMING CHAIN COVER SUB-ASSEMBLY (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
15. REMOVE RADIATOR HOSE NO.2
16. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
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
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
SST 09213-54015 (91651-60855), 09330-00021, 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
SST 09032-00100
46. REMOVE OIL STRAINER SUB-ASSEMBLY
47. REMOVE OIL PAN SUB-ASSEMBLY





48. REMOVE TIMING CHAIN COVER
a. Remove the 2 nuts, then separate the water by-pass pipe No.1.





b. Remove the 19 bolts and 2 nuts shown in the illustration.

HINT: If the vehicle is equipped with air conditioning, bolts A are already removed since they are for installing the idle pulley w/ bracket.





c. Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver.

HINT: Tape the screwdriver tip before use.

NOTICE: Be careful not to damage the contact surfaces of the cylinder head, cylinder block and timing chain cover.





d. Remove the 4 O-rings.





e. Using a 10 mm socket hexagon wrench, remove the head straight screw plug.
49. REMOVE WATER INLET
50. REMOVE THERMOSTAT
51. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
52. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
SST 09223-5001 0
53. INSTALL THERMOSTAT
54. INSTALL WATER INLET





55. INSTALL TIMING CHAIN COVER
a. Apply adhesive to the head straight screw plug.
Adhesive: Part No.08833-00070, THREE BOND 1324 or equivalent
b. Using a 10 mm socket hexagon wrench, install the head straight screw plug.
Torque: 17 Nm (170 kgf-cm, 12 ft. lbs.)





c. Install 4 new O-rings onto the timing chain cover as shown in the illustration.
d. Apply continuous beads of seal packing to the places shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent





Seal width





NOTICE:
- Remove any oil from the contact surface.
- Install the chain cover within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
- Do not start the engine for at least 4 hours after installation.





e. Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover onto the crankshaft.
f. Loosely install the timing chain cover with the 19 bolts and 2 nuts, but do not tighten the bolts and nuts yet.





g. Provisionally install the timing chain cover with the 19 bolts and 2 nuts.

NOTICE: If the vehicle is equipped with air conditioning, install bolts A' and B' when installing the idle pulley w/ bracket since they are for this purpose.

HINT: Bolt length:
75 mm (2.95 inch) for bolt A, B
87 mm (3.43 inch) for bolt C
95 mm (3.74 inch) for bolt D
35 mm (1.37 inch) for bolt E

h. Fully tighten the bolts and nuts, except bolts A, in the following order: Area 1, Area 3 and then Area 2.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
i. Fully tighten the bolts A in the following order: Area 2 and then Area 3.
Torque: 46 Nm (469 kgf-cm, 34 ft. lbs.)





j. Fully tighten the bolts E in Area
4. Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)





k. Install a new gasket, then install the water by-pass pipe No.1 with the 2 nuts.
Torque: 18 Nm (178 kgf-cm, 13 ft. lbs.)
56. INSTALL OIL PAN SUB-ASSEMBLY
57. INSTALL OIL STRAINER SUB-ASSEMBLY
58. INSTALL OIL PAN SUB-ASSEMBLY NO.2
59. INSTALL OIL LEVEL GAGE SUB-ASSEMBLY
60. INSTALL CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021
61. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
62. INSTALL INTAKE MANIFOLD TO HEAD GASKET NO.1
63. INSTALL CAMSHAFT POSITION SENSOR
64. INSTALL CRANKSHAFT POSITION SENSOR
65. INSTALL IDLE PULLEY ASSEMBLY W/BRACKET (W/ AIR CONDITIONING)
66. INSTALL IDLER PULLEY SUB-ASSEMBLY NO.1
67. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
68. INSTALL GENERATOR ASSEMBLY
69. INSTALL INTAKE AIR CONNECTOR
70. INSTALL REAR END PLATE
a. Install the rear end plate with the 2 bolts.
Torque: 18 Nm (178 kgf-cm, 13 ft. lbs.)
71. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY (AUTOMATIC TRANSMISSION)
SST 09213-54015 (91651-60855), 09330-00021
72. INSTALL FLYWHEEL SUB-ASSEMBLY (MANUAL TRANSMISSION)
SST 09213-54015 (9165-60855), 09330-00021
73. INSTALL CLUTCH DISC ASSEMBLY (MANUAL TRANSMISSION)
74. INSTALL CLUTCH COVER ASSEMBLY (MANUAL TRANSMISSION)
75. INSTALL ENGINE ASSEMBLY
76. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
77. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY
78. INSTALL EXHAUST PIPE ASSEMBLY FRONT
79. INSTALL EXHAUST PIPE ASSEMBLY TAIL
80. CONNECT ENGINE WIRE
81. CONNECT AIR INJECTION SYSTEM NO.1 HOSE
82. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY
83. CONNECT FUEL HOSE NO.2
84. CONNECT FUEL HOSE
85. INSTALL WATER HOSE SUB-ASSEMBLY
86. INSTALL RADIATOR HOSE INLET
87. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
88. INSTALL RADIATOR HOSE NO.2
89. INSTALL VANE PUMP ASSEMBLY
90. INSTALL AIR CLEANER CASE
a. Install the air cleaner case with the 3 bolts.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
91. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
92. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
93. INSTALL FAN SHROUD
94. INSTALL RADIATOR SUPPORT TO FRAME SEAL LH
95. INSTALL BATTERY TRAY
96. INSTALL BATTERY
97. ADD ENGINE OIL
98. ADD ENGINE COOLANT
99. CHECK ENGINE OIL LEVEL
100. CHECK FOR FUEL LEAKAGE
101. CHECK FOR ENGINE COOLANT LEAKAGE
102. CHECK FOR OIL LEAKAGE
103. CHECK FOR EXHAUST GAS LEAKAGE
104. INSTALL 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.)
105. INSTALL 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.)
106. INSTALL HOOD SUB-ASSEMBLY
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