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Home >> Toyota >> 2005 >> Tacoma PreRunner 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 (PRE-RUNNER/4WD))



































COMPONENTS

REPLACEMENT
1. REMOVE BATTERY
2. DRAIN ENGINE COOLANT
3. DRAIN ENGINE OIL
4. REMOVE POWER STEERING LINK ASSEMBLY
5. REMOVE DIFFERENTIAL CARRIER ASSEMBLY FRONT (4WD DRIVE TYPE)
6. REMOVE V-BANK COVER
7. REMOVE RADIATOR SUPPORT TO FRAME SEAL LH
8. REMOVE FAN SHROUD
9. REMOVE AIR CLEANER ASSEMBLY
10. 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.
11. REMOVE WATER INLET





12. SEPARATE PUMP ASSEMBLY, VANE
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
14. SEPARATE COOLER COMPRESSOR ASSEMBLY





15. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
a. Remove the 5 bolts, then remove the V-ribbed belt tensioner.
16. REMOVE IDLER PULLEY SUB-ASSEMBLY NO.2
a. Remove the 2 bolts, then remove the idler pulley No.2.
17. REMOVE IDLER PULLEY SUB-ASSEMBLY NO.1
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), 09330-00021





b. Using the pulley set bolt and SST, remove the crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05030)





19. REMOVE OIL PAN SUB-ASSEMBLY NO.2
a. Remove the 10 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.
- 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.





c. Remove the 17 bolts and 2 nuts.





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
23. REMOVE IGNITION COIL ASSEMBLY
24. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
25. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
26. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
27. REMOVE WT SENSOR
28. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
29. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL





30. 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.
31. 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.
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 CHAIN VIBRATION DAMPER NO.2
a. Remove the 2 chain vibration dampers No.2.
35. REMOVE CHAIN SUB-ASSEMBLY
36. INSTALL CHAIN TENSIONER SLIPPER





37. 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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