Toyota 4Runner 2001-06

Timing Chain & Sprockets

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Removal & Installation



  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the engine undercover.
  6.  
  7. Drain the engine coolant and the engine oil.
  8.  
  9. On 4WD vehicles, remove the front differential.
  10.  
  11. 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.  
    3. Remove the set nuts, the fluid coupling with the fan, and the water pump pulley.
    4.  

  12.  
  13. Remove the cylinder head.
  14.  
  15. If equipped with A/C, remove the A/C belt, compressor, and the bracket.
  16.  
  17. Remove the alternator adjusting bar and bracket.
  18.  
  19. Unbolt and remove the crankshaft position sensor and O-ring.
  20.  



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Fig. Exploded view of the engine timing chains and related components-2RZ-FE and 3RZ-FE engines



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Fig. The crankshaft position sensor is located below the water pump-2RZ-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.  
  3. Unbolt the flywheel housing undercover and dust seal.
  4.  
  5. Remove the oil pan.
  6.  
  7. Unsecure the oil strainer and gasket.
  8.  
  9. Remove the crankshaft pulley, a pulley bolt remover will be needed.
  10.  



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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 crankshaft-2RZ-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.  
  3. Remove the chain cover assembly. Remove the bolts shown by the arrows.
  4.  
  5. Remove the No. 1 timing chain and camshaft gear.
  6.  
  7. Remove the crankshaft timing gear.
  8.  
  9. 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.
  10.  



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Fig. Remove the bolts securing the chain dampers-2RZ-FE and 3RZ-FE engines



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Fig. The oil jet is secured by a single bolt-2RZ-FE and 3RZ-FE engines

  1. On the 2RZ-FE remove the crankshaft position sensor rotor and the timing chain oil jet.
  2.  
  3. 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.  
    3. Remove the bolt and the No. 2 damper.
    4.  
    5. Remove the two bolts and the No. 3 damper.
    6.  
    7. Unsecure the nut and the No. 2 tensioner.
    8.  

  4.  



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Fig. Lock the plunger with an appropriate pin-2RZ-FE and 3RZ-FE engines



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Fig. Fastener locations for the tensioner and damper-2RZ-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.  
    3. Remove the balance shaft gear with the shaft.
    4.  
    5. Remove the No. 2 timing chain with the No. 2 crankshaft timing sprocket.
    6.  

  2.  
  3. Remove the No. 4 vibration damper.
  4.  

To install:

  1. Install the No. 4 vibration dampener.
  2.  
  3. 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.  
    3. Fit the other marked link of the No. 2 chain onto the sprocket behind the large timing mark of the balance shaft gear.
    4.  
    5. 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.
    6.  
    7. Install the bolt to the balance shaft gear and tighten to 18 ft. lbs. (25 Nm).
    8.  
    9. Check each timing mark is matched with the corresponding mark link.
    10.  

  4.  



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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 marks-2RZ-FE and 3RZ-FE engines

  1. Install the No. 2, No. 3 vibration dampers and the No. 2 chain tensioner, as follows:
  2.  

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.  
  3. Install the No. 3 damper with the bolts, tighten to 13 ft. lbs. (18 Nm).
  4.  
  5. Install the No. 2 damper, tighten to 20 ft. lbs. (27 Nm).
  6.  
  7. Remove the pin from the No. 2 chain tensioner and free the plunger.
  8.  

  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.  
  3. 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.  
    3. Install the slipper, tighten to 20 ft. lbs. (27 Nm).
    4.  
    5. Check that the slipper moves smoothly.
    6.  

  4.  
  5. Install the crankshaft timing gear.
  6.  
  7. Install the No. 1 timing chain and camshaft timing gear.
  8.  



Click image to see an enlarged view

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 installed-2RZ-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.  
  3. 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.
  4.  
  5. Tie the No. 1 chain with a wire or cord, make sure it does not come loose.
  6.  

  1. Install the timing chain cover assembly.
    1. Remove the old cover gaskets and install new gaskets.
    2.  
    3. Slide the cover assembly over the dowels and the pump spline. Tighten the following:
    4.  

  2.  



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Fig. Timing cover fastener identification-2RZ-FE and 3RZ-FE engines



12mm A bolts-14 ft. lbs. (20 Nm)
 
12mm B bolts-18 ft. lbs. (25 Nm)
 
14mm bolts-32 ft. lbs. (44 Nm)
 
14mm nut-14 ft. lbs. (20 Nm)
 

  1. Attach the water bypass pipe.
  2.  
  3. Remove the cord or wire from the chain.
  4.  

  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.  
  3. Install the oil strainer, tighten to 13 ft. lbs. (18 Nm).
  4.  
  5. Attach the oil pan with fresh sealant, tighten the mounting bolts to 108 inch lbs. (13 Nm).
  6.  
  7. Attach the flywheel housing undercover and dust seal.
  8.  
  9. Attach the stiffener plates on the 2WD vehicles, tighten to 27 ft. lbs. (37 Nm).
  10.  
  11. Install the crankshaft position sensor with a new O-ring.
  12.  
  13. Install the alternator, adjusting bar and bracket.
  14.  
  15. For vehicles with A/C, install the compressor and bracket.
  16.  
  17. Install the cylinder head.
  18.  
  19. 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.
  20.  
  21. On 4WD vehicles, install the front differential and driveshaft assemblies.
  22.  
  23. Lower the vehicle.
  24.  
  25. Adjust the drive belt tension.
  26.  
  27. Fill with engine coolant and engine oil.
  28.  
  29. Install the engine undercover.
  30.  
  31. Connect the negative battery cable.
  32.  
  33. Start the engine and check the ignition timing.
  34.  
  35. Recheck fluid levels and top off.
  36.  


CAUTION
Valve timing in any engine is important, but in a Dual Over Head Camshaft (DOHC) engine like this, it is critical. Improperly performed, cam timing belt replacement can ruin the engine. Work carefully and verify that all timing marks properly align before attempting to start the engine.

1gr-FE Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove the battery.
  8.  
  9. Remove the engine appearance cover.
  10.  
  11. Remove the accessory drive belt.
  12.  
  13. Remove the engine fan.
  14.  
  15. Remove the air intake assembly.
  16.  
  17. Remove the engine oil dipstick tube.
  18.  
  19. Remove the water inlet.
  20.  
  21. Separate the power steering pump and hang securely from the engine. Do not disconnect power steering lines.
  22.  
  23. Remove the alternator.
  24.  
  25. Separate the A/C compressor and hang securely from the engine. Do not disconnect the refrigerant lines.
  26.  
  27. Disconnect the crankshaft position sensor.
  28.  
  29. Remove the accessory drive belt tensioner.
  30.  
  31. Remove the No. 1 and No. 2 idler pulleys. The No. 1 idler pulley is marked -DOUBLE- on the pulley face to distinguish it from the No. 2 idler pulleys.
  32.  
  33. Remove the crankshaft pulley.
  34.  
  35. Remove the lower and upper oil pans.
  36.  
  37. Remove the upper intake manifold (air surge tank).
  38.  
  39. Remove the ignition coils.
  40.  
  41. Remove the valve covers.
  42.  
  43. Disconnect the two oil control valve connectors. Remove the mounting bolts and camshaft timing oil control valves.
  44.  
  45. Remove the VVT sensor on each side.
  46.  
  47. Remove the oil filter. Remove the mounting bolts and nuts and remove the oil filter bracket and gasket.
  48.  
  49. Remove the 24 mounting bolts and 2 nuts of the timing chain cover. There are two different sizes of bolts. Correctly identify each bolt, its length and location. Remove the timing chain cover by prying between the timing chain cover and cylinder head or block with a suitable prying device.

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    Fig. Location of the prying points to remove the timing chain cover-4.0L (1GR-FE) Engine

  50.  
  51. Reinstall the crankshaft pulley set bolt, and turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block to set the No. 1 cylinder at Top Dead Center (TDC). Check that the timing marks of the camshaft sprockets (also called timing gears) are aligned with the timing marks of the bearing cap as shown in the illustration. If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks.

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    Fig. Align the set key with the timing on the block to set the No. 1 cylinder at TDC-4.0L (1GR-FE) Engine



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    Fig. Check the timing marks on the camshaft sprockets to ensure the No. 1 cylinder is at TDC-4.0L (1GR-FE) Engine

  52.  
  53. Remove the timing chain cover plate and gasket. While turning the stopper plate of the tensioner upward, push in the plunger of the chain tensioner as shown in the illustration.
  54.  
  55. While turning the stopper plate of the tensioner downward, insert a bar or pin into the holes in the stopper plate and tensioner to fix the stopper plate.
  56.  
  57. Remove the chain tensioner.
    WARNING
    Never rotate the crankshaft with the chain tensioner removed.



    Click image to see an enlarged view

    Fig. Push in the plunger of the timing chain tensioner and insert a pin to secure the stopper plate.

  58.  
  59. Remove the chain tensioner slipper.
  60.  
  61. Using a 10 mm hex wrench, remove the idle gear shaft and idle gear.
  62.  
  63. Remove the No. 2 chain vibration damper.
  64.  
  65. Remove the timing chain.
  66.  
  67. To remove the camshaft sprockets and secondary timing chain, the camshafts must be removed. For additional information, refer to the following topic: -Camshaft and Valve Lifters, Removal & Installation-.
  68.  

To install:

  1. Install the camshaft sprockets and secondary timing chain, if removed. For additional information, refer to the following topic: -Camshaft and Valve Lifters, Removal & Installation-.
  2.  
  3. Install the chain tensioner slipper.
  4.  
  5. With the stopper plate still secured with a pin or bar, install the chain tensioner. Tighten the mounting bolts to 80 inch lbs. (9 Nm).
  6.  
  7. Set the No. 1 cylinder to TDC. Align the timing marks of the camshaft sprockets and bearing caps. Use the crankshaft pulley bolt, turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block.

    Click image to see an enlarged view

    Fig. Place the chain on the crankshaft sprocket, aligning the yellow link with the timing mark on the sprocket-4.0L (1GR-FE) Engine

  8.  
  9. Align the mark link (yellow) with the timing mark of the crankshaft sprocket.

    Click image to see an enlarged view

    Fig. Install the chain on the camshaft sprockets, aligning the orange links with the timing marks-4.0L (1GR-FE) Engine

  10.  
  11. Align the mark links (orange) with the timing marks of the camshaft sprockets, and install the chain.
  12.  
  13. Install the No. 2 chain vibration damper.
  14.  
  15. Apply a light coat of engine oil to rotating surface of the No. 1 idle gear shaft. Temporarily install the No. 1 idle gear shaft and No. 1 idle gear with the No. 2 idle gear shaft, while aligning the knock pin of the No. 1 idle gear shaft with the knock pin groove of the cylinder block. Use a 10 mm hex wrench, tighten the No. 2 idler gear shaft to 44 ft. lbs. (60 Nm). Remove the pin from the chain tensioner.

    Click image to see an enlarged view

    Fig. Idler gear installation-4.0L (1GR-FE) Engine

  16.  
  17. Using a suitable pry tool, pry out the old timing chase case oil seal. Using a suitable seal installer and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge. Apply multipurpose grease to the oil seal lip.

    Click image to see an enlarged view

    Fig. Pry out the old timing chain cover oil seal (top) and install a new seal (bottom) before installing the timing chain cover.

  18.  
  19. Remove any old gasket material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.
  20.  
  21. Replace the O-ring to the left hand cylinder head as shown.

    Click image to see an enlarged view

    Fig. Install a new O-ring to the left hand cylinder head-4.0L (1GR-FE) Engine

  22.  
  23. Apply a continuous bead of gasket sealer 1 / 8 inch in diameter to the four location on the cylinder block and cylinder head shown. Apply a continuous 1 / 8 inch diameter bead of silicone gasket material to the timing chain cover as shown. If parts are not assembled within three minutes of applying time, the sealer starts to skin over, the effectiveness of the sealer is lost and the sealer must be removed and reapplied.

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    Fig. Gasket material application points on the block-4.0L (1GR-FE) Engine



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    Fig. Apply a continuous bead of silicone gasket material to the case as shown-4.0L (1GR-FE) Engine

  24.  
  25. 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. Install the timing chain cover mounting bolts and nuts to their original locations. Insert each bolt and only hand tighten to each bolt is properly aligned. Tighten all bolts and nuts to 17 ft. lbs. (23 Nm). Align the oil pump drive rotor and crankshaft timing gear keyway with installing the timing chain cover-4.0L (1GR-FE) Engine

    Click image to see an enlarged view

    Fig. Timing chain cover bolt identification Bolts A are 0.98 inches long; Bolts B are 2.17 inches long-4.0L (1GR-FE) Engine

  26.  
  27. Install the oil filter bracket with a new gasket. Tighten the three bolts and two nuts to 14 ft. lbs. (19 Nm).
  28.  
  29. Apply a light coat of engine oil to the O-ring of the VVT sensor and install the sensors on each side. Tighten the bolt to 71 inch lbs. (8 Nm).
  30.  
  31. Insert the camshaft timing oil control valves to each cylinder head, and tighten the 2 bolts to 80 inch lbs. (9 Nm).
  32.  
  33. Install the valve covers.
  34.  
  35. Install the ignition coils.
  36.  
  37. Install the intake air surge tank.
  38.  
  39. Install the upper and lower oil pans.
  40.  
  41. Install the crankshaft pulley.
  42.  
  43. Install the No. 1 idler pulley. Tighten the bolt to 40 ft. lbs. (54 Nm).
  44.  
  45. Install the No. 2 idler pulleys. Tighten the bolts to 29 ft. lbs. (39 Nm).
  46.  
  47. Install the accessory drive belt tensioner. Tighten the five bolts to 27 ft. lbs. (36 Nm).

    Click image to see an enlarged view

    Fig. The accessory drive belt tensioner mounting bolts are two different lengths. Bolts A are 2.76 inches long; Bolts B are 1.3 inches long-4.0L (1GR-FE) Engine

  48.  
  49. Install the A/C compressor, alternator and power steering pump.
  50.  
  51. Install the water inlet and connect the coolant bypass hoses.
  52.  
  53. Install a new O-ring to the oil dipstick tube. Apply a light coat of clean engine oil to the O-ring. Push the dipstick tube into the guide hole of the oil pan. Tighten the mounting bolt to 80 inch lbs. (9 Nm).
  54.  
  55. Install the air intake assembly.
  56.  
  57. Install the engine fan with the fan shroud.
  58.  
  59. Install the accessory drive belt.
  60.  
  61. Install the battery.
  62.  
  63. Install the engine appearance cover.
  64.  
  65. Refill the engine cooling system to the correct level.
  66.  
  67. Refill the engine oil to the correct level.
  68.  
  69. Start the engine and check for leaks, then inspect the ignition timing.
  70.  

 
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