Toyota 13506-AD010
Timing Chain

The service of the timing chain requires initial removal of the power steering link assembly then front differential carrier assembly on 4WD models and finally draining engine coolant and oil. The next step requires removal of the battery along with V-bank cover and upper radiator support seal through the removal of 11 clips. First disconnect the fluid coupling assembly before removing the fan and generator V belt afterward and continuing with the fluid coupling assembly removal. Remove the No. 2 ventilation hose while unfastening the air cleaner assembly and extracting both the oil level gauge guide and its gauge and O-ring. The vane pump assembly needs separation by disconnecting the P/S oil pressure switch connector and removing two bolts. Take care not to damage the pulley against any other component. Users must remove the generator assembly along with the cooler compressor assembly and V-ribbed belt tensioner assembly after unbolting 5 pieces and then disassemble both No. 2 and No. 1 idler pulley sub-assemblies. The crankshaft pulley removal requires Special Service Tool: 09213-54015 (91651-60855), 09330-00021 to secure the pulley during bolt loosening before completely removing both components with a combination of 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05030). The No. 2 oil pan sub-assembly needs to be removed through the process of removing 10 bolts and 2 nuts while using Special Service Tool: 09032-00100 to cut off the applied sealer. Start the engine removal process by removing the oil strainer sub-assembly then the oil pan sub-assembly, intake air surge tank, ignition coil assembly along with both cylinder head cover sub-assemblies. The servicing steps begin with disconnecting the 2 connectors from the camshaft timing oil control valve assembly while removing 2 bolts before proceeding to remove the VVT sensor with the timing chain or belt cover sub-assembly. Set No. 1 cylinder at TDC/compression position by positioning the crankshaft set key on the cylinder block timing line while the camshaft timing gear marks must align with bearing caps. Before rotating the crankshaft remove the No. 1 chain tensioner assembly while using care and then take out the chain tensioner slipper followed by the No. 1 idle gear shaft and No. 2 chain vibration damper and chain sub-assembly. The installation process begins with the chain tensioner slipper and then leads to the No. 1 chain tensioner assembly but requires proper fixation of the stopper plate with a 3.5 mm bar. Install the chain sub-assembly by positioning the mark links with the timing marks before adding the No. 2 chain vibration damper, No. 1 idle gear shaft, and securing the No. 2 idle gear shaft with a 10 mm hexagon wrench. Position the timing gear case or timing chain case oil seal together with the timing chain or belt cover sub-assembly and VVT sensor and camshaft timing oil control valve assembly before tightening all bolts to 10 Nm. The system combination includes both cylinder head cover sub-assemblies and ignition coil assembly and intake air surge tank. The oil pan sub-assembly installation requires removal of old packing materials and addition of fresh parts including an oil pump O-ring along with Toyota Genuine Seal Packing Black or Three Bond 1207B or Equivalent seal packing materials applied before installing the assembly with 17 bolts and 2 nuts that should be equally tightened. Place the oil strainer sub-assembly with its new gasket before installing the No. 2 oil pan sub-assembly while the process requires applying seal packing to all components then uniformly tightening bolts and nuts. To install the crankshaft pulley you need Special Service Tool: 09213-54015 (91651-60855), 09330-00021 and you should torque the pulley set bolt to 250 Nm. The installation of No. 1 idler pulley sub-assembly together with No. 2 idler pulley sub-assembly and V-ribbed belt tensioner assembly requires proper torque on all bolts. The last step includes installation of the cooler compressor assembly and generator assembly with vane pump assembly followed by connecting the P/S oil pressure switch connector then proceeding to attach the water inlet and oil level gauge guide until completion with air cleaner assembly installation and final connection of the No. 2 ventilation hose. Place a fluid coupling assembly followed by generator V belt installations then perform a fluid coupling assembly torque procedure and finally install the upper radiator support seal and battery alongside the front differential carrier assembly and power steering link assembly. Seamlessly install the V-bank cover by torquing it to 7.5 Nm while checking for leaks and also checking the ignition timing.

The procedure to install the 1GR-FE timing chain requires starting with the chain tensioner slipper installation followed by the No. 1 chain tensioner assembly including pushing the plunger while doing clockwise and counterclockwise rotations with a 3.5 mm (0.138 in.) bar until fixed before torquing the 2 bolts at 10 Nm (102 kgf-cm, 7 ft-lbf). Follow this by positioning the No. 1 cylinder at TDC/compression while your alignment task focuses on matching the timing marks of camshaft timing gears and bearing caps. At this point you can install the crankshaft pulley set bolt before using the crankshaft to make the set key match the timing line. Before lifting the chain into place you should position the yellow mark link adjacent to the crankshaft timing gear and the orange mark links should be applied to the camshaft timing gears. Place the No. 2 chain vibration dampers before you apply engine oil to the No. 1 idle gear shaft and fasten both components together through their knock pin position. Use the 10 mm hexagon wrench to fasten the No. 2 idle gear shaft to 60 Nm (612 kgf-cm, 44 ft-lbf) before taking out the bar from the chain tensioner. Embed the timing gear case oil seal, timing chain or belt cover sub-assembly, VVT sensor and camshaft timing oil control valve assembly with both 10 Nm (102 kgf-cm, 7 ft-lbf) bolts. Proceed to install the cylinder head cover sub-assemblies, ignition coil assembly at 10 Nm (102 kgf-cm, 7 ft-lbf), intake air surge tank, and oil pan sub-assembly, ensuring to remove old packing and apply a new O-ring to the oil pump, followed by a continuous bead of seal packing (3 to 4 mm (0.12 to 0.16 in.)) before tightening the oil pan bolts and nuts uniformly: bolt A at 21 Nm (214 kgf-cm, 15 ft-lbf), bolt B at 21 Nm (214 kgf-cm, 15 ft-lbf), bolt C at 10 Nm (102 kgf-cm, 7 ft-lbf), and nut at 21 Nm (214 kgf-cm, 15 ft-lbf). Install the 4 housing bolts at 37 Nm (377 kgf-cm, 27 ft-lbf) and the flywheel housing under the cover. After installing the new gasket and 2 nuts at 9.0 Nm (92 kgf-cm, 80 in-lbf) onto the oil strainer sub-assembly proceed with installing the No. 2 oil pan sub-assembly by applying seal packing then tightening the bolts and nuts uniformly at 10 Nm (102 kgf-cm, 7 ft-lbf). Apply Special Service Tools 09213-54015 91651-60855 and 09330-00021 to install the crankshaft pulley before mounting the No. 1 idler pulley sub-assembly at 54 Nm (551 kgf-cm, 40 ft-lbf). When installing the No. 2 idler pulley sub-assembly obey specific guidelines that depend on whether the idler pulley cover plate exists and perform needed replacements. Place the V-ribbed belt tensioner assembly then tightening bolt 1 and 2 to 36 Nm (367 kgf-cm, 27 ft-lbf) while following by additional bolt installation at the same torque value. After attaching the vane pump assembly with 2 bolts at 43 Nm (438 kgf-cm, 32 ft-lbf) you should connect the P/S oil pressure switch connector before installing the water inlet. The oil level gauge guide needs installation following application of a new O-ring with a 9.0 Nm (92 kgf-cm, 80 in-lbf) torque setting, then install the oil level gauge, air cleaner assembly and connect the No. 2 ventilation hose. Fitting the fluid coupling assembly together with the fan and generator V belt requires a complete torque tightening of the fluid coupling assembly. The service procedure includes first installing the radiator support seal upper before placing the battery and differential carrier assembly front and power steering link assembly. Along with oil and coolant addition follow a leak check then secure the V-bank cover using 2 nuts at 7.5 Nm (76 kgf-cm, 66 in-lbf) before inspecting the ignition timing.

The first step to timing chain removal from the 1GR-FE engine requires you to disconnect the battery and drain engine coolant followed by oil. The power steering link assembly must be removed before the timing chain replacement while both 2WD and 4WD owners follow additional steps to detach the front differential carrier assembly. Start the removal of the fan together with the generator assembly before you separate the cooler compressor assembly and then eliminate the V-ribbed belt tensioner assembly by removing its five bolts. Use Special Service Tool: 09032-00100 with the No. 2 oil pan sub-assembly to cut off the applied sealer before removing this assembly with the oil strainer sub-assembly and the oil level gauge guide. Proceed to break the oil pan sub-assembly but maintain intact contact surfaces, then take away the air cleaner assembly, throttle body bracket, oil baffle plate, surge tank stays, intake air surge tank, ignition coil assembly, camshaft timing oil control valve assembly, VVT sensor, water inlet, and both cylinder head covers. The timing chain or belt cover sub-assembly needs removal with no damage to contact surfaces when all 2 nuts and 24 bolts are taken out. Gently extract the timing gear case or timing chain case oil seal while adjusting No. 1 compression to TDC through alignment of the crankshaft set key with the timing line together with appropriate camshaft timing gears' marks positioning. Before removing the crankshaft with a detached chain tensioner assembly replace the stopper plate then proceed with tensioner removal. The last step includes removal of the chain tensioner slipper and No. 1 idle gear and No. 2 chain vibration dampers followed by extraction of the chain sub-assembly.

The repair procedure for the timing chain starts with draining engine fluids followed by battery removal and subsequent steps including the V-bank cover then radiator until the fan with fluid coupling is loose enough to remove the drive belt and fan. Performance of the servicing process starts with the air cleaner separation followed by the removal of intake air surge tank and cylinder head cover. Then disconnect the VVT sensor and oil level gauge guide alongside the oil level gauge and O-ring. Start the vane pump disassembly by removing its P/S oil pressure switch connector while taking out the bolts but avoiding the pulley area. First reverse the order of operations by taking out the crankshaft pulley with Special Service Tool: 09213-54015 (91651-60855), 09330-00021 while holding the tool with Special Service Tool: 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05031) to complete removal. Then extract the idler pulleys No.1 and No.2 and the V-ribbed belt tensioner followed by the cooler compressor and generator. Begin the oil pan No.2 removal process by disconnecting bolts along with nuts followed by sealer cutting using Special Service Tool: 09032-00100 until the oil strainer and gasket can be detached. Remove the oil pan while also taking out the water inlet together with the timing chain cover but maintain intact contact surfaces during this process. The mechanic should handle the TDC/compression position of No.1 cylinder before removing the components in this sequence: chain tensioner No.1 followed by idle gear No.1 then chain vibration damper No.2 and finally the timing chain and crankshaft timing sprocket and No.2 timing chain. The mechanic must exercise caution to avoid harming the cylinder head and valve lifter. Check that the elongation of both No.1 and No.2 timing chains does not surpass 146.8 mm (5.780 inch). It is crucial to measure three assembly components in their minimum dimensions - 115.5 mm (4.547 inch) for the camshaft gear assembly and 73.1 mm (2.878 inch) for its sprockets and 61.0 mm (2.402 inch) for the crankshaft sprocket. The standard minimum diameter measurement for idle gear No.1 should be 61.0 mm (2.402 inch) and idle gear shaft oil clearance needs to be checked to ensure it stays within limits. A thorough test of chain tensioners should produce smooth results while chain tensioner slipper and vibration damper wear inspection must replace components when measuring depths reach 1.0 mm (0.039 inch).

Service of the timing chain system starts by disconnecting the hood sub-assembly on a 2007 Toyota Truck Tacoma 2WD L4-2.7L (2TR-FE) model before discharging fuel system pressure and unfastening No. 1 and No. 2 engine under cover sub-assemblies from 4WD and Pre-Runner models. Service the engine requires draining of oil and coolant before removing the battery tray and battery together. Move toward taking off the radiator support to frame seal LH together with fan shroud, air cleaner cap, filter element and case before separating vane pump assembly without touching hose connections. First disconnect the No. 2 radiator hose followed by disassembly of the magnetic clutch from the compressor and then removal of wires and hoses. Thorough engine assembly removal requires the exhaust pipe assembly together with front exhaust pipe assembly and transmission unit to be taken out first. When changing manual transmission parts the technician must remove clutch cover together with the disc and the flywheel yet automatic transmission maintenance requires removing drive plate and ring gear. Move forward by taking out the rear end plate, intake air connector, generator assembly, V-ribbed belt tensioner assembly and No. 1 idler pulley sub-assembly. When the vehicle comes equipped with an air conditioning system the idle pulley assembly with bracket should be removed first followed by the crankshaft position sensor, camshaft position sensor, No. 1 intake manifold to head gasket and cylinder head cover and crankshaft pulley while the No. 1 cylinder requires positioning at TDC/compression. The technician removes the crankshaft pulley and its bolt by first using Special Service Tool: 09213-54015 (91651-60855), 09330-00021 to loosen the pulley bolt before employing Special Service Tool: 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09954-05021) to detach both components. The maintenance technician should extract the oil level gage sub-assembly and No. 2 oil pan sub-assembly by removing 18 bolts and 2 nuts then carefully sever the sealer application with Special Service Tool: 09032-00100. The service technician should begin by removing the oil strainer sub-assembly and oil pan sub-assembly together with the timing chain cover and timing chain guide and No. 1 chain tensioner assembly. After these components are removed the chain tensioner slipper will be exposed followed by the removal of the No. 1 chain vibration damper, chain sub-assembly, crankshaft timing gear or sprocket and No. 2 and No. 3 chain vibration damper and the No. 2 chain tensioner assembly. The installer should align the No. 2 chain sub-assembly to timing marks before placing the chain tensioner assembly, No. 3 chain vibration damper, No. 2 chain vibration damper together with crankshaft timing gear then adding the No. 1 chain vibration damper followed by chain sub-assembly while making sure timing marks match their painted indicators. Place all installation pieces in sequence that includes the chain tensioner slipper and No. 1 chain tensioner assembly and timing chain guide and timing chain cover. The installation of the oil pan sub-assembly includes seal packing before using its 16 bolts together with two nuts to secure it while completing the installation with an oil strainer sub-assembly. Follow with the No. 2 oil pan sub-assembly, oil level gage sub-assembly, crankshaft pulley, cylinder head cover, No. 1 intake manifold to head gasket, camshaft position sensor, crankshaft position sensor, idle pulley assembly with bracket, No. 1 idler pulley sub-assembly, V-ribbed belt tensioner assembly, generator assembly, intake air connector, rear end plate, drive plate and ring gear sub-assembly for automatic transmission, flywheel sub-assembly, clutch disc assembly, clutch cover assembly, engine assembly, automatic transmission assembly, and manual transmission unit assembly. The exhaust pipe assemblies must be installed next with engine wire connections followed by various hose installations before fitting the compressor and magnetic clutch and sequence with the No. 2 radiator hose, vane pump assembly, air cleaner case, air cleaner filter element, air cleaner cap, fan shroud, radiator support to frame seal LH, battery tray, and battery. Sequence these tasks by adding engine oil and coolant followed by leak tests before installing the hood sub-assembly and its sub-components No. 1 and No. 2.

Install the water inlet, oil level gauge guide with a new O-ring, and air cleaner assembly.

Install the water inlet, oil level gauge guide with a new O-ring, and air cleaner assembly.

Remove the No. 1 chain tensioner assembly, taking care not to rotate the crankshaft with the chain tensioner removed, and fix the stopper plate while pushing in the plunger.

Remove chain tensioner assembly No. 1, ensuring not to rotate the crankshaft with the tensioner removed, and while pushing in the plunger, fix the stopper plate with a 3.5 mm bar before removing the 2 bolts.

Begin by removing the power steering link assembly, differential carrier assembly front (4WD drive type), draining the engine coolant and oil, and removing the battery, V-bank cover, and radiator support seal upper by taking out 11 clips.

Remove the No. 1 chain tensioner assembly, ensuring not to rotate the crankshaft with the chain tensioner removed, and fix the stopper plate while removing the 2 bolts.

Begin by installing the chain tensioner slipper.

Install the chain sub-assembly, No. 2 chain vibration damper, and idle sprocket assembly, applying engine oil as needed.

To maintain optimal performance and reliability of the timing chain system.

Set the crankshaft position by turning the crankshaft pulley set bolt to position the crankshaft set key horizontally to the left, ensuring the correct angle to avoid piston and valve contact during camshaft installation.

Apply seal packing (Part No. 08826-00080) to the oil pan sub-assembly, install the oil strainer sub-assembly, and No. 2 oil pan sub-assembly, ensuring proper torque specifications are followed.

Remove the oil strainer sub-assembly, then the oil pan sub-assembly by prying it off carefully.

For manual transmission, remove the clutch cover assembly, clutch disc assembly, and flywheel sub-assembly; for automatic transmission, remove the drive plate and ring gear sub-assembly.