Toyota Tundra 2001-06

Timing Chain Cover, Chain, Sprockets, & Seal

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Removal & Installation



4.0L Engine


Click image to see an enlarged view

Fig. Timing chain and related components-4.0L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable. Disconnect the positive battery cable. Remove the battery.
  6.  
  7. Remove the V bank cover.
  8.  
  9. Drain the engine coolant. Remove the radiator.
  10.  
  11. Loosen the fluid coupling assembly (fan). Remove the drive belt. Remove the fan assembly.
  12.  
  13. Remove the air cleaner assembly. Remove the oil level gauge. Remove the water inlet.
  14.  
  15. Separate the vane pump assembly (power steering pump). Remove the alternator. Remove the air conditioning compressor and position it to the side.
  16.  
  17. Remove the belt tensioner assembly. Remove the idler pulley number two subassembly. Remove the idler pulley number one subassembly. Remove the crankshaft pulley.
  18.  
  19. Remove the lower oil pan. Remove the oil strainer and pickup tube assembly. Remove the upper oil pan.
  20.  
  21. Remove the intake manifold. Remove the ignition coil assembly. Remove the cylinder head cover assembly.
  22.  
  23. Remove the camshaft timing oil control valve assembly. Remove the VVT sensor. Remove the oil filter bracket subassembly.
    NOTE
    Carefully remove the cover by prying between the cover and the cylinder head or block with a suitable tool. Be sure to cover the tip of the suitable tool prior to usage. Be careful not to damage the contact surfaces of the cylinder block, cylinder head and timing chain cover.

  24.  
  25. Using the crankshaft pulley set bolt, turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block. If not aligned at TDC of the compression stroke, turn the crankshaft one complete revolution, in the direction of rotation
  26.  
  27. While turning the stopper plate of the tensioner upward, push the plunger of the chain tensioner. While turning the stopper plate of the tensioner downward, insert a 0.138 inch diameter bar into the holes in the stopper plate and tensioner to hold the stopper plate.
  28.  
  29. Remove the two bolts, and then remove the chain tensioner.
  30.  
  31. Remove the chain tensioner slipper. Remove the idle gear shaft number two, idle gear number one and idle gear shaft number one.
  32.  
  33. Remove the number two chain vibration damper. Remove the timing chain subassembly.
  34.  

To install:

  1. Install the chain tensioner slipper.
  2.  
  3. While turning the stopper plate of the tensioner clockwise, push in the plunger of the chain tensioner. While turning the stopper plate of the tensioner counterclockwise, insert a 0.138 inch diameter bar into the holes in the stopper plate and tensioner to hold the stopper plate.
  4.  
  5. Install the chain tensioner. Tighten the bolts to 7.4 ft. lbs.
  6.  
  7. Position the engine at TDC on the compression stroke. Align the camshaft timing gears and bearing caps. Using the crankshaft pulley set bolt, align the crankshaft set key with the timing line of the cylinder.

    Click image to see an enlarged view

    Fig. Timing chain alignment-4.0L engine

  8.  
  9. Align the yellow mark line with the timing mark of the crankshaft timing link. Align the orange mark links with the timing marks of the camshaft timing gears, and install the chain.
  10.  
  11. Install the number two chain vibration damper.
  12.  
  13. Apply a light coat of clean engine oil to the rotating surface of the idle gear shaft number one.
  14.  
  15. Temporarily install the idle gear shaft number one together with idle gear shaft number two, while aligning the knock pin of idle gear shaft number one with the knock pin groove of the cylinder block.
    NOTE
    Be care of the idle gear direction.

  16.  
  17. Tighten the idle gear shaft number two to 44 ft. lbs. Remove the bar from the chain tensioner.
  18.  
  19. Install a new front case oil seal. Install a new O-ring onto the left cylinder head.
  20.  
  21. Apply continuous beads (0.12-0.16 inch in diameter) of seal packing, part number 08826-00080 or equivalent to the four locations shown in the illustration.
  22.  
  23. Apply continuous beads (0.12-0.16 inch in diameter) of seal packing, part number 08826-00080 or equivalent to all parts except the water pump part: for the water pump part use, part number 08826-00080 or equivalent, to the timing chain cover. Do not apply seal packing to portion -A-.
    NOTE
    Remove any oil from the contact surfaces. Install the timing chain case cover within three minutes and tighten the bolts within fifteen minutes of applying the seal packing.

  24.  
  25. Align the key way of the oil pump drive motor with the rectangular portion of the crankshaft timing gear and slide the timing chain case cover into place.
  26.  
  27. Install the timing chain case cover bolts. Tighten the bolts and nuts uniformly in several steps to 17 ft. lbs.
    NOTE
    Do not wrap the chain and slipper over the timing chain case cover seal line.

  28.  
  29. Continue the installation in the reverse order of the removal procedure.
  30.  
  31. When installing the cylinder head cover apply a continuous bead (0.08-0.12 inch) of seal packing, part number 08826-00080 or equivalent, to the cylinder head. Install the seal washers onto the bolts. Install the cylinder head cover bolts and nuts. Tighten bolts -A- to 7.4 ft. lbs. Tighten bolts -B- to 80 inch lbs. Tighten nuts to 80 inch lbs.
    NOTE
    Be sure to remove any oil from the contact surfaces of the cylinder head cover and the cylinder head. Install the cover within three minutes after applying the seal packing. Tighten the bolts to specification within fifteen minutes after installing the cover. Do not add engine oil for at least two hours after installing the cover.

  32.  
  33. Be sure to fill the engine with the proper grade and type engine coolant.
  34.  
  35. Be sure to fill the engine with the proper grade and type engine oil.
  36.  
  37. Start the engine and check for leaks, correct as required.
  38.  

 
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