Timing Chain Components & Instalation Toyota Hilux 22R-E: Preparation of Removal

Timing Chain Components & Instalation
Toyota Hilux 22R-E
PREPARATION OF REMOVAL
1. REMOVE CYLINDER HEAD
(See page EG1–16)
2. REMOVE RADIATOR
(See page EG1–230)
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 sixteen bolts and 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. (with 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) (with 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 and 09330–00021
(c) Using SST, remove the crankshaft pulley.

SST 09213–310231
HINT: If the front seal is to be replaced, see page
EG1–236.
5. REMOVE NO. 1 WATER BY–PASS PIPE
Remove the two bolts and pipe.
6. REMOVE FAN BELT ADJUSTING BAR

(a) (w/ PS)
Remove the bolt and PS lower bracket.
(b) Remove the three bolts and bar.
7. DISCONNECT HEATER WATER OUTLET PIPE

Remove the two 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 three 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 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 two 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
(See page EG1–39)
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 dam–
pers.
(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 sur–
face. 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: 8 mm bolt 13 N–m(130kgf–cm, 9ft–Ibf)
10 mm bolt 13 N–m(400kgf–cm, 29ft–lbf)
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 cylin–
der head.
Torque: 13N–m(130kgf–cm, 9ft–Ibf)
6. INSTALL HEATER WATER OUTLET PIPE
Connect the heater water outlet pipe to the timing
chain cover with the two bolts.
7. INSTALL NO.1 WATER BY–PASS PIPE

Install the pipe with the two 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: 157N–m(1,600kgf–cm, 116ft–lbf)
(c) (with 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 with fan with the four nuts.
(b) Place the drive belt onto each pulley.
(c) Stretch the belt tight and tighten the four nuts.
10. ADJUST DRIVE BELT TENSION
(See page MA–6)
11. (with A/C) INSTALL A/C COMPRESSOR BRACKET,
COMPRESSOR AND BELT
(See page MA–6)
12. (w/PS) INSTALL PS BELT
(See page MA–6)
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 pai–

nted 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 excess amount to the sur–
face. 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 tubs and
reinstall the cap after using the seal packing.
(d) Install the oil pan over the studs on the block with the
sixteen bolts and two nuts. Torque the bolts and nuts.
Torque: 13N–m(130kgf–cm, 9ft–lbf)
(e) Lower the engine and install the engine mounting
bolts.
(f) Install the engine under cover.
POST INSTALLATION
1. INSTALL RADIATOR
2. INSTALL CYLINDER HEAD
(See page EG1–34)
3. (4WD) INSTALL FRONT DIFFERENTIAL
(See SA section)

Timing Chain Components & Instalation Toyota Hilux 22R-E: Preparation of Removal

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What are the steps to remove the timing chain components?

What are the steps to remove the timing chain components?

What are the inspection procedures for the timing chain components?

What are the inspection procedures for the timing chain components?

Timing Chain Components & Instalation

Toyota Hilux 22R-E

4. REMOVE OIL PAN

TIMING CHAIN REMOVAL

3. REMOVE FLUID COUPLING WITH FAN AND

4. REMOVE CRANKSHAFT PULLEY

(c) Using SST, remove the crankshaft pulley.

6. REMOVE FAN BELT ADJUSTING BAR

7. DISCONNECT HEATER WATER OUTLET PIPE

8. REMOVE CHAIN COVER ASSEMBLY

9. REMOVE CHAIN AND CAMSHAFT SPROCKET

(c) Wrap the chain around the sprocket.

2. MEASURE CHAIN TENSIONER

3. MEASURE CHAIN DAMPERS

2. PLACE CHAIN ON CAMSHAFT SPROCKET

3. INSTALL OIL PUMP DRIVE SPLINE

4. INSTALL TIMING CHAIN COVER ASSEMBLY

5. INSTALL FAN BELT ADJUSTING BAR

7. INSTALL NO.1 WATER BY–PASS PIPE

8. INSTALL CRANKSHAFT PULLEY

9. INSTALL WATER PUMP PULLEY AND FLUID

NOTICE: Do not use a solvent which will affect the pai–

(c) Apply seal packing to the oil pan as shown in the

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