Timing Chain removal & Installation on a toyota 22RE engine

TIMING CHAIN
COMPONENTS
PREPARATION OF REMOVAL
1. REMOVE CYLINDER HEAD
(See page EG1-16 )
2. REMOVE RADIATOR
(See page EG1-236 )
3. 4WD:
REMOVE FRONT DIFFERENTIAL
(See SA section)
4. REMOVE OIL PAN
(a) Remove the engine undercover.
(b) Remove the engine mounting bolts.
(c) 2WD: Place a jack under the transmission and raise the engine
approx. 25 mm (0.98 in.)
(d) Remove the 16 bolts and 2 nuts.
(e) Using SST and brass bar, separate the oil pan from the cylinder block.
SST 09032-00100
HINT: When removing the oil pan, be careful not to damage
the oil pan flange.
TIMING CHAIN REMOVAL
1. w/ PS: REMOVE PS BELT
2. w/ A/C: REMOVE A/C BELT, COMPRESSOR AND BRACKET
3. REMOVE FLUID COUPLING WITH FAN AND WATER
PUMP PULLEY
(a) Loosen the water pump pulley set bolts.
(b) Loosen the belt adjusting bolt and pivot bolt of the generator,
and remove the drive belt.
(c) Remove the set nuts, fluid coupling with fan and water pump
pulley.
4. REMOVE CRANKSHAFT PULLEY
(a) w/ A/C (w/o Air pump) or w/PS (w/ Air pump): Remove the
No.2 crankshaft pulley.
(b) Using SST to hold the crankshaft pulley, loosen the pulley
bolt. SST 09213-70010, 09330-00021
(c) Using SST, remove the crankshaft pulley.
SST 09213-310231
HINT: If the front seal is to be replaced, see page EG1-242 .
5. REMOVE NO.1 WATER BYPASS PIPE
Remove the 2 bolts and pipe.
6. REMOVE FAN BELT ADJUSTING BAR
(a) w/ PS: Remove the bolt and PS lower bracket.
(b) Remove the 3 bolts and bar.
7. DISCONNECT HEATER WATER OUTLET PIPE
Remove the 2 bolts, and disconnect heater water outlet pipe.
8. REMOVE CHAIN COVER ASSEMBLY
(a) Remove timing chain cover bolts shown by the arrows.
(b) Using a plastic faced hammer, loosen the chain cover and
remove it.
9. REMOVE CHAIN AND CAMSHAFT SPROCKET
(a) Remove the chain from the damper.
(b) Remove the cam sprocket and chain together.
10. REMOVE PUMP DRIVE SPLINE AND CRANKSHAFT SPROCKET
If the oil pump drive spline and sprocket cannot be removed
by hand, use SST to remove them together.
SST 09213-36020
11. REMOVE GASKET MATERIAL ON CYLINDER BLOCK
COMPONENTS INSPECTION
1. MEASURE CHAIN AND SPROCKET WEAR
(a) Measure the length of 17 links with the chain fully stretched.
(b) Make the same measurements at least 3 other places
selected at random.
Chain elongation limit at 17 links: 147.0 mm (5.787 in.)
If over the limit at any one place, replace the chain.
(c) Wrap the chain around the sprocket.
(d) Using a caliper gauge, measure the outer sides of the chain
rollers as shown. Measure both sprockets.
Crankshaft sprocket minimum:
59.4 mm (2.339 in.)
Camshaft sprocket minimum:
113.8 mm (4.480 in.)
If the measurement is less than minimum, replace the chain
and 2 sprockets.
2. MEASURE CHAIN TENSIONER
Using a caliper gauge, measure the tensioner as shown.
Tensioner minimum:
11.0 mm (0.433 in.)
If the tensioner is worn or less than minimum, replace the
chain tensioner.
3. MEASURE CHAIN DAMPERS
Using a micrometer, measure each damper.
Damper wear limit:
0.5 mm (0.020 in.)
If either damper is worn or less than minimum, replace the
damper.

TIMING CHAIN INSTALLATION
1. INSTALL CRANKSHAFT SPROCKET AND CHAIN
(a) Turn the crankshaft until the shaft key is on top.
(b) Slide the sprocket over the key on the crankshaft.
(c) Place the timing chain on the sprocket with the single bright
chain link aligned with the timing mark on the sprocket.
2. PLACE CHAIN ON CAMSHAFT SPROCKET
(a) Place the timing chain on the sprocket so that the bright chain
link is aligned with the timing mark on the sprocket.
(b) Make sure the chain is positioned between the dampers.
(c) Turn the camshaft sprocket counterclockwise to take the
slack out of the chain.
3. INSTALL OIL PUMP DRIVE SPLINE
Slide the oil pump drive spline over the crankshaft key.
HINT: If the oil pump drive spline is difficult to install by hand,
install using SST.
SST 09608-35014 (09608-06040)
4. INSTALL TIMING CHAIN COVER ASSEMBLY
(a) Remove the old cover gaskets. Clean the gasket surface.
Install new gaskets over the dowels.
(b) Slide the cover assembly over the dowels and pump spline.
(c) Insert the bolts as shown and torque them.
Torque:
13 N-m (130 kgf-cm, 9 ft-lbf) for 8 mm bolt
39 N-m (400 kgf-cm, 29 ft-lbf) for 10 mm bolt
5. INSTALL FAN BELT ADJUSTING BAR
(a) Temporarily install the adjusting bar to the alternator.
(b) Install the adjusting bar to the chain cover and cylinder head.
Torque: 13 N-m (130 kgf-cm, 9 ft-lbf)
6. INSTALL HEATER WATER OUTLET PIPE
Connect the heater water outlet pipe to the timing chain cover
with the 2 bolts.
7. INSTALL NO.1 WATER BYPASS PIPE
Install the pipe with the 2 bolts.
8. INSTALL CRANKSHAFT PULLEY
(a) Install the crankshaft pulley and bolt.
(b) Using SST to hole the crankshaft pulley, torque the bolt.
SST 09213-70010 and 09660-00021
Torque: 157 NVm (1,600 kgfVcm, 116 ft.lbf)
(c) w/ A/C:
Install the NO.2 crankshaft pulley.
9. INSTALL WATER PUMP PULLEY AND FLUID COUPLING
WITH FAN
(a) Temporarily install the water pump pulley and fluid coupling
withfan with the 4 nuts.
(b) Place the drive belt onto each pulley.
(c) Stretch the belt tight and tighten the 4 nuts.
10. ADJUST DRIVE BELT TENSION
(See page MA-8 )
11. w/ A/C:
INSTALL A/C COMPRESSOR BRACKET, COMPRESSOR
AND BELT
(See page MA-8 )
12. w/PS:
INSTALL PS BELT
(See page MA-8 )
13. INSTALL OIL PAN
(a) Remove any old packing material and be careful not to drop
any oil on the contacting surfaces of the oil pan and cylinder
block.
• Using a razor blade and gasket scraper, remove all the
packing (FIPG) material from the gasket surfaces.
• Thoroughly clean all components to remove all the
loose material.
• Clean both sealing surfaces with a non-residue solvent.
NOTICE: Do not use a solvent which will affect the painted surfaces.
(b) Apply seal packing to the joint part of the cylinder block and
chain cover, cylinder block and rear oil seal retainer.
Seal packing:
Part No.08826-00080 or equivalent
(c) Apply seal packing to the oil pan as shown in the illustration.
Seal packing:
Part No.08826-00080 or equivalent
• Install a nozzle that has been cut to a 5-mm (0.20 in.)
opening.
HINT: Avoid applying an excessive amount to the surface. Be
especially careful near oil passages.
• If parts are not assembled within 5 minutes of applying
the seal packing, the effectiveness of the seal packing
is lost and the seal packing must be removed and
reapplied.
• Immediately remove the nozzle from the tube and
reinstall the cap after using the seal packing.
(d) Install the oil pan over the studs on the block with the 16 bolts
and 2 nuts. Torque the bolts and nuts.
Torque: 13N-m (130 kgf-cm, 9 ft-lbf)
(e) Lower the engine and install the engine mounting bolts.
(f) Install the engine under cover.
14. INSTALL RADIATOR
15. INSTALL CYLINDER HEAD
(See page EG1-34 )
16. 4WD:
INSTALL FRONT DIFFERENTIAL
(See SA section)