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Replacement

TIMING CHAIN OR BELT COVER SUB-ASSEMBLY (1GR-FE(PRE RUNNER/4WD))



































COMPONENTS

REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE
2. REMOVE BATTERY
3. DRAIN ENGINE COOLANT
4. DRAIN ENGINE OIL
5. REMOVE POWER STEERING LINK ASSEMBLY
6. REMOVE DIFFERENTIAL CARRIER ASSEMBLY FRONT (4WD DRIVE TYPE)
7. REMOVE V-BANK COVER
8. REMOVE RADIATOR SUPPORT TO FRAME SEAL LH
9. REMOVE FAN SHROUD
10. REMOVE AIR CLEANER ASSEMBLY
11. REMOVE OIL LEVEL GAUGE GUIDE
12. REMOVE WATER INLET
13. SEPARATE PUMP ASSEMBLY, VANE
14. REMOVE GENERATOR ASSEMBLY
15. SEPARATE COOLER COMPRESSOR ASSEMBLY
16. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
17. REMOVE IDLER PULLEY SUB-ASSEMBLY NO.2
18. REMOVE IDLER PULLEY SUB-ASSEMBLY NO.1
19. REMOVE CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05030)
20. REMOVE OIL PAN SUB-ASSEMBLY NO.2
SST 09032-00100
21. REMOVE OIL STRAINER SUB-ASSEMBLY
22. REMOVE OIL PAN SUB-ASSEMBLY
23. REMOVE INTAKE AIR SURGE TANK
24. REMOVE IGNITION COIL ASSEMBLY
25. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
26. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
27. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
28. REMOVE WT SENSOR
29. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY
a. Remove the 3 bolts, 2 nuts, oil filter bracket and gasket.





30. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
a. Remove the 24 bolts and 2 nuts.





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

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

c. Remove the O-ring from the LH cylinder head.
31. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
32. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
SST 09226-10010
33. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.





b. Install a new O-ring onto the LH cylinder head as shown in the illustration.





c. Apply continuous beads of seal packing (diameter 3 to 4 mm (0.12 to 0.16 inch)) to the 4 locations shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent





d. Apply continuous beads of seal packing (diameter 3 to 4 mm (0.12 to 0.16 inch)) to the timing chain cover as shown in the illustration.
Seal packing: Water pump part: Part No.08826-00100 or equivalent Other parts: Part No.08826-00080 or equivalent

NOTICE:
- Install the timing chain cover within 3 minutes after applying seal packing. Timing chain cover bolts and nuts must be tightened within 15 minutes of installation. Otherwise the seal packing must be removed and reapplied.
- Do not apply seal packing to portion A shown in the illustration.





e. Align the key way of the oil pump drive rotor with the rectangular portion of the crankshaft timing gear, and slide the timing chain cover into place.





f. Install the timing chain cover with the 24 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque: 23 Nm (235 kgf-cm, 17 ft. lbs.)

NOTICE: Pay attention not to wrap the chain and slipper over the timing chain cover seal line.





HINT: Each bolt length is as above.

34. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY
a. Install a new gasket and oil filter bracket with the 3 bolts and 2 nuts.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
35. INSTALL WT SENSOR
36. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
37. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
38. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
39. INSTALL IGNITION COIL ASSEMBLY
40. INSTALL INTAKE AIR SURGE TANK
41. INSTALL OIL PAN SUB-ASSEMBLY
42. INSTALL OIL STRAINER SUB-ASSEMBLY
43. INSTALL OIL PAN SUB-ASSEMBLY NO.2
44. INSTALL CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021
45. INSTALL IDLER PULLEY SUB-ASSEMBLY NO.1
46. INSTALL IDLER PULLEY SUB-ASSEMBLY NO.2
47. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
48. INSTALL COOLER COMPRESSOR ASSEMBLY
49. INSTALL GENERATOR ASSEMBLY
50. INSTALL PUMP ASSEMBLY, VANE
51. INSTALL WATER INLET
52. INSTALL OIL LEVEL GAUGE GUIDE
53. INSTALL AIR CLEANER ASSEMBLY
54. INSTALL FAN SHROUD
55. INSTALL RADIATOR SUPPORT TO FRAME SEAL LH
56. INSTALL DIFFERENTIAL CARRIER ASSEMBLY FRONT (4WD DRIVE TYPE)
57. INSTALL POWER STEERING LINK ASSEMBLY
58. INSTALL BATTERY
59. ADD ENGINE OIL
60. ADD ENGINE COOLANT
61. ADD DIFFERENTIAL OIL (4WD DRIVE TYPE)
62. INSPECT DIFFERENTIAL OIL (4WD DRIVE TYPE)
63. ADD POWER STEERING FLUID
64. BLEED POWER STEERING FLUID
65. CHECK FOR ENGINE OIL LEAKAGE
66. CHECK FOR ENGINE COOLANT LEAKAGE
67. CHECK FOR FUEL LEAKAGE
68. CHECK FOR EXHAUST GAS LEAKAGE
69. CHECK POWER STEERING FLUID LEAKAGE
70. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
71. INSTALL V-BANK COVER
72. INSPECT IGNITION TIMING
SST 09843-18040
73. INSPECT ENGINE IDLING SPEED
SST 09843-18030
74. INSPECT COMPRESSION
75. INSPECT CO/HC

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