Position the number one piston at TDC on the compression stroke, confirming alignment of the timing mark on the crankshaft pulley/vibration damper with the "O" mark on the timing chain cover and the camshaft sprocket marks with the marks on the camshaft front bearing caps. Remove the crankshaft pulley/vibration damper without rotating the engine from TDC, and if it does rotate, reposition it back to TDC. Next, take off the drive belt tensioner and crankshaft position sensor from the timing chain cover, along with the bolt securing the wiring harness. Remove the oil pan, then take out the timing chain cover mounting fasteners and carefully pry the cover off from several locations, noting the different sizes of the mounting bolts for reassembly. Once the cover is off, remove the O-rings from the crankcase, followed by the top chain guide mounting bolt and guide. Let the tensioner plunger extend until a 0.06 inch (1.5 mm) pin can be inserted into the alignment holes of the stopper plate and the tensioner, then release the tensioner ensuring the pin is secured. Remove the mounting bolts and the timing chain tensioner, then take out the timing chain tensioner pivot arm/chain guide and the stationary timing chain guide. Lift the timing chain off the camshaft sprockets and remove the timing chain and crankshaft sprocket as an assembly from the engine, ensuring to mark the front of the chain if it will be reused. To remove the camshaft sprockets, loosen the bolts while holding the lug on the camshaft with a wrench, noting the identification marks before removal. Visually inspect all parts for wear and damage, checking the timing chain for loose pins, cracks, worn rollers, and side plates, as well as the sprockets for hook-shaped, chipped, and broken teeth. Measure the timing chain for stretching and the diameter of the timing sprockets for wear, replacing them as a set if necessary. Check the chain guides for excessive wear and replace them if scoring or wear exceeds acceptable limits. Remove all traces of old sealant from the timing chain cover and the mating surfaces of the engine block and cylinder head. Position the camshafts with the dowel pins at the top, then install both camshaft sprockets in their original locations, applying medium strength thread locking compound to the bolt threads and tightening them while holding the camshaft. Temporarily install the crankshaft pulley bolt and rotate the crankshaft until the keyway is pointing to the 10 o'clock position, then align the TDC marks on the camshaft sprockets. Install the stationary timing chain guide, loop the timing chain around the exhaust camshaft sprocket aligning the yellow colored link with the timing mark, and guide the chain into the stationary chain guide while aligning the crankshaft sprocket with the pink colored link. Slip the timing chain around the intake camshaft sprocket, rotating the camshaft counterclockwise to align the timing mark and colored link before installing the chain onto the sprocket teeth. Remove the string holding the chain to the crankshaft sprocket, rotate the crankshaft clockwise until the keyway is at the 12 o'clock position, and install the tensioner guide and mounting bolt. Install a new gasket and the tensioner with the mounting bolts, tightening them and allowing the plunger to contact the tensioner guide. Confirm the number one piston is still at TDC and that the timing marks are aligned with the colored links on the chain. Install the top chain guide mounting bolt and guide, apply RTV sealant to the timing chain cover sealing surfaces, place the cover in position, and install the bolts in their original locations, tightening them evenly. Install the passenger's side mounting bracket to the front of the timing chain cover and tighten the bolts in sequence. Install the crankshaft pulley/vibration damper, rotate the engine clockwise at least two revolutions, and reposition the number one piston at TDC, visually confirming the alignment of the timing marks. The remainder of installation follows the reverse order of removal.
Posted by ToyotaPartsDeal Specialist 
