Saturday, October 15, 2011

Timing chain Routing for 1997 Toyota Tacoma 2.7L 4 cylinder?


Timing Chain


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REMOVAL & INSTALLATION



2RZ-FE and 3RZ-FE Engines
  1. Disconnect the negative battery cable.
  2. Raise and safely support the vehicle.
  3. Remove the engine undercover.
  4. Drain the engine coolant and the engine oil.
  5. On 4WD vehicles, remove the front differential.
  6. Remove the alternator belt, fan with coupling and the water pump pulley:
    1. Loosen the water pump pulley bolts. Loosen the belt adjusting bolt and the pivot bolt of the alternator and remove the drive belt.
    2. Remove the set nuts, the fluid coupling with the fan, and the water pump pulley.
  7. Remove the cylinder head.
  8. If equipped with A/C, remove the A/C belt, compressor, and the bracket.
  9. Remove the alternator adjusting bar and bracket.
  10. Unbolt and remove the crankshaft position sensor and O-ring.


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Fig. Exploded view of the engine timing chains and related components2RZ-FE and 3RZ-FE engines


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Fig. The crankshaft position sensor is located below the water pump2RZ-FE and 3RZ-FE engines


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Fig. Remove the bolts securing the stiffener plates
  1. On 2WD vehicles, remove the stiffener plates.
  2. Unbolt the flywheel housing undercover and dust seal.
  3. Remove the oil pan.
  4. Unsecure the oil strainer and gasket.
  5. Remove the crankshaft pulley, a pulley bolt remover will be needed.


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Fig. The crankshaft pulley is removed with a puller. Note the crankshaft center bolt is partly installed to protect the threads in the crankshaft2RZ-FE and 3RZ-FE engines


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Fig. Remove the bolts securing the front cover (arrows)2RZ-FE and 3RZ-FE engines
  1. Remove the water bypass pipe.
  2. Remove the chain cover assembly. Remove the bolts shown by the arrows.
  3. Remove the No. 1 timing chain and camshaft gear.
  4. Remove the crankshaft timing gear.
  5. Remove the No. 1 timing chain tensioner slipper and No. 1 vibration damper. On the 2RZ-FE, remove the two bolts and the damper. On the 3RZ-FE, remove the bolt, nut and No. 1 damper.


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Fig. Remove the bolts securing the chain dampers2RZ-FE and 3RZ-FE engines


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Fig. The oil jet is secured by a single bolt2RZ-FE and 3RZ-FE engines
  1. On the 2RZ-FE remove the crankshaft position sensor rotor and the timing chain oil jet.
  2. On the 3RZ-FE engine, remove the No. 2 and No. 3 vibration dampers and the No. 2 chain tensioner as follows:
    1. Install a pin to the No. 2 tensioner and lock the plunger.
    2. Remove the bolt and the No. 2 damper.
    3. Remove the two bolts and the No. 3 damper.
    4. Unsecure the nut and the No. 2 tensioner.


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Fig. Lock the plunger with an appropriate pin2RZ-FE and 3RZ-FE engines


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Fig. Fastener locations for the tensioner and damper2RZ-FE and 3RZ-FE engines
  1. Remove the balance shaft driven gear, shaft, No. 2 timing chain and the No. 2 crankshaft sprocket, as follows:
    1. Unbolt the balance shaft driven gear.
    2. Remove the balance shaft gear with the shaft.
    3. Remove the No. 2 timing chain with the No. 2 crankshaft timing sprocket.
  2. Remove the No. 4 vibration damper.
To install:
  1. Install the No. 4 vibration dampener.
  2. Install the No. 2 timing chain, No. 2 crankshaft timing sprocket, balance shaft drive gear and shaft as follows:
    1. Install the No. 2 chain by matching the marked links with the timing marks on the crankshaft sprocket and balance shaft timing sprocket.
    2. Fit the other marked link of the No. 2 chain onto the sprocket behind the large timing mark of the balance shaft gear.
    3. Insert the balance shaft gear shaft through the balance shaft drive gear so that it fits into the thrust plate hole. Align the small timing mark of the balance shaft drive gear with the timing mark of the balance shaft timing gear.
    4. Install the bolt to the balance shaft gear and tighten to 18 ft. lbs. (25 Nm).
    5. Check each timing mark is matched with the corresponding mark link.


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Fig. With No.1 cylinder at TDC of the compression stroke and the weights of the balance shafts at the bottom, install the balance shaft chain and sprockets using care to align all of the timing marks2RZ-FE and 3RZ-FE engines
  1. Install the No. 2, No. 3 vibration dampers and the No. 2 chain tensioner, as follows:
Assemble the chain tensioner with the pin installed, then remove the pin after assembly.
  1. Install the No. 2 chain tensioner with the nut, tighten to 13 ft. lbs. (18 Nm).
  2. Install the No. 3 damper with the bolts, tighten to 13 ft. lbs. (18 Nm).
  3. Install the No. 2 damper, tighten to 20 ft. lbs. (27 Nm).
  4. Remove the pin from the No. 2 chain tensioner and free the plunger.
  1. On the 2RZ-FE engines, install the oil jet and crankshaft position sensor rotor. Make sure the front mark of the cavity of the rotor is facing forward.
  2. Install the No. 1 timing chain tensioner slipper and the No. 1 vibration damper.
    1. Install the No. 1 damper, tighten to 22 ft. lbs. (29 Nm).
    2. Install the slipper, tighten to 20 ft. lbs. (27 Nm).
    3. Check that the slipper moves smoothly.
  3. Install the crankshaft timing gear.
  4. Install the No. 1 timing chain and camshaft timing gear.


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Fig. Align the camshaft gear timing mark between the marked links on the timing chain, then align the timing mark on the crankshaft gear with its marked link on the chain. Wire the chain together under the gear to keep it from coming off when the head is installed2RZ-FE and 3RZ-FE engines
  1. Align the timing mark between the marked link of the No. 1 timing chain, and install the No. 1 timing chain to the gear.
  2. Align the timing mark of the crankshaft timing gear with the mark of the No. 1 timing chain, then install the No. 1 timing chain.
  3. Tie the No. 1 chain with a wire or cord, make sure it does not come loose.
  1. Install the timing chain cover assembly.
    1. Remove the old cover gaskets and install new gaskets.
    2. Slide the cover assembly over the dowels and the pump spline. Tighten the following:


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Fig. Timing cover fastener identification2RZ-FE and 3RZ-FE engines


12mm A bolts14 ft. lbs. (20 Nm)
12mm B bolts18 ft. lbs. (25 Nm)
14mm bolts32 ft. lbs. (44 Nm)
14mm nut14 ft. lbs. (20 Nm)

  1. Attach the water bypass pipe.
  2. Remove the cord or wire from the chain.
  1. Install the crankshaft pulley, tighten the bolt to 193 ft. lbs. (260 Nm). On A/C vehicles, install the crankshaft pulleys with bolts and tighten to 18 ft. lbs. (25 Nm).
  2. Install the oil strainer, tighten to 13 ft. lbs. (18 Nm).
  3. Attach the oil pan with fresh sealant, tighten the mounting bolts to 108 inch lbs. (13 Nm).
  4. Attach the flywheel housing undercover and dust seal.
  5. Attach the stiffener plates on the 2WD vehicles, tighten to 27 ft. lbs. (37 Nm).
  6. Install the crankshaft position sensor with a new O-ring.
  7. Install the alternator, adjusting bar and bracket.
  8. For vehicles with A/C, install the compressor and bracket.
  9. Install the cylinder head.
  10. Install the water pump pulley and the fluid coupling with the fan. Place the belt onto each pulley. While pulling the belt tight, tighten the four nuts.
  11. On 4WD vehicles, install the front differential and driveshaft assemblies.
  12. Lower the vehicle.
  13. Adjust the drive belt tension.
  14. Fill with engine coolant and engine oil.
  15. Install the engine undercover.
  16. Connect the negative battery cable.
  17. Start the engine and check the ignition timing.
  18. Recheck fluid levels and top off.
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Timing Chain Cover and Seal

2RZ-FE and 3RZ-FE Engines
This is a difficult and lengthy procedure requiring removal of many components including the front differential assembly and the cylinder head. This procedure can also be performed with the engine out of the vehicle, which may be an option, depending on the equipment and facilities available. If other heavy engine work is required (for example, a failed timing chain may have caused valve/piston damage) it may just be easier to remove the engine as an assembly and perform the work on a suitable engine stand.
The following procedure is based on Toyota's Tacoma in-frame procedure.


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Fig. Numerous components must be removed to service the timing chain cover2RZ-FE and 3RZ-FE engines


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Fig. Use care to install the timing chain cover bolts in their proper locations. Torque to specification2RZ-FE and 3RZ-FE Engines
  1. Disconnect the negative battery cable.
  2. Raise and safely support the vehicle.
  3. Drain the engine coolant and the engine oil.
  4. Remove the cylinder head.
  5. Remove the radiator.
  6. On 4WD vehicles, remove the front differential.
  7. Remove the oil pan.
  8. If equipped with power steering, remove the power steering belt.
  9. If equipped with A/C, remove the A/C belt, compressor, and the bracket.
  10. Remove the fluid coupling with the fan and the water pump pulley, as follows:
    1. Loosen the water pump pulley bolts. Loosen the belt adjusting bolt and the pivot bolt of the alternator and remove the drive belt.
    2. Remove the set nuts, the fluid coupling with the fan, and the water pump pulley.
  11. Remove the crankshaft pulley.
  12. Remove the water bypass pipe.
  13. Remove the fan belt adjusting bar. With power steering, remove the lower power steering bracket.
  14. Disconnect the heater water outlet pipe.
  15. Remove the chain cover assembly.
To install:
  1. Remove the old cover gaskets and install new gaskets.
  2. Slide the timing chain cover assembly over the dowels and the pump spline. Tighten the 8mm bolts to 9 ft. lbs. (13 Nm) and the 10mm bolts to 29 ft. lbs. (13 Nm).
  3. Install the fan belt adjusting bar to the chain cover and the cylinder head. Tighten to 9 ft. lbs. (13 Nm).
  4. Install the heater water outlet pipe.
  5. Install the water bypass pipe.
  6. Install the crankshaft pulley and tighten the bolt to 116 ft. lbs. (157 Nm).
  7. Install the water pump pulley and the fluid coupling with the fan. Place the belt onto each pulley. While pulling the belt tight, tighten the four nuts.
  8. Adjust the drive belt tension.
  9. If removed, install the A/C compressor bracket, the compressor and the belt.
  10. If removed, install the power steering belt.
  11. Apply Formed In-Place Gasket (FIPG) sealer to the joint part of the cylinder block, the chain cover, the cylinder block, the rear oil seal retainer and the oil pan. Install the oil pan over the studs on the block and tighten the nuts and bolts to 9 ft. lbs. (13 Nm).
  12. Install the radiator.
  13. Install the cylinder head.
  14. If removed, install the front differential.
  15. Fill with engine coolant and engine oil.
  16. Connect the negative battery cable.
  17. Start the engine and check the ignition timing.

SEAL REPLACEMENT



Cover Removed
  1. Unbolt the timing chain cover assembly. Be careful to loosen only the correct bolts.
  2. Pry out the seal from the cover with a flat-bladed tool.
  3. It is a good idea to remove the oil pump from the timing cover and replace the O-ring.


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Fig. Remove the seal with a flat-blade tool and hammer


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Fig. Install the seal using a proper sized driver
To install:
  1. Clean and inspect the timing cover area. Install new gaskets around the dowel areas and pump spline.
  2. Apply multi-purpose grease to the new oil seal lip.
  3. Tap the seal into place with SST 0922350010/60010 or equivalent, and a hammer. Do this until the seal surface is flush with the cover edge.
  4. Install the cover; tighten the bolts as specified for your engine.
  5. If the oil pump was removed, install a new O-ring behind the pump prior to installation.
Cover Installed
  1. Unbolt and remove the oil pump.
  2. Using a knife, carefully cut off the oil seal lip. With a flat-bladed tool (with tape around it), pry the seal from the cover.


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Fig. Carefully cut off the oil seal lip, and then pry the seal from the cover


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Fig. Drive the seal flush against the cover edge
To install:
  1. Apply multi-purpose grease to the new oil seal lip.
  2. Tap the seal into place with SST 0922350010/60011 or equivalent seal driver, and a hammer. Do this until the seal surface is flush with the cover edge.
  3. Install the oil pump with a new O-ring.
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