Timing Chain Tensioner

This procedure replaces the timing chain tensioner on the 2AR-FE 2.5L I4 engine, requiring removal of the timing chain cover and precise tensioner installation with proper engine timing verification.

Warnings

Tools required

Parts

• Timing chain tensioner assembly × 1 — Use OEM Toyota part 13540-36010 or equivalent
• Timing cover gasket × 1 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Crankshaft pulley bolt (recommended replacement) × 1 — Use OEM specification
• Oil pan drain plug gasket × 1 — Use OEM specification

Fluids

• Toyota Genuine 0W-20 — 5 qt
• Toyota Super Long Life Coolant (Pink) — 2 qt

Preparation

1. Ensure engine is completely cold. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and wait 90 seconds for airbag system discharge
3. Drain engine oil completely and drain coolant from radiator drain cock
4. Remove engine cover by pulling upward on clips
5. Remove air intake assembly and air filter housing
6. Support engine from below with floor jack and wood block under oil pan
7. Remove right engine mount to provide access to timing cover area
8. Label and photograph all connector and hose positions before removal

Procedure

1. 1

   Remove accessory drive belt and components
   Rotate belt tensioner clockwise to relieve tension and remove accessory drive belt. Remove alternator mounting bolts and position alternator aside without disconnecting wiring. Remove power steering pump bolts and secure pump aside without disconnecting lines.
2. 2

   Remove crankshaft pulley
   Install crankshaft holding tool to prevent rotation. Use breaker bar to loosen crankshaft pulley bolt (clockwise is loosening on this engine). Remove bolt and slide pulley off crankshaft using gentle prying if needed. Inspect pulley for wear or wobble.
   ⚠This bolt is extremely tight. Ensure holding tool is secure before applying force to prevent engine rotation.
3. 3

   Remove valve cover
   Disconnect ignition coils and PCV hoses from valve cover. Remove valve cover bolts in reverse of tightening sequence (outside to inside pattern). Carefully lift valve cover and gasket away. Clean any residual gasket material from cylinder head mating surface using plastic scraper.
4. 4

   Remove timing chain cover
   Remove all timing chain cover bolts, noting the different lengths and positions (8mm bolts are longer than 10mm bolts). There are approximately 15-17 bolts total around the perimeter. Carefully pry cover away from engine block using designated pry points. Remove old gasket and thoroughly clean all mating surfaces.
   ⚠Do not pry between machined aluminum surfaces. Use only designated pry slots to prevent warping.
5. 5

   Verify timing marks alignment
   Rotate crankshaft to TDC position on cylinder #1 (compression stroke). Verify timing marks on both camshaft sprockets align with marks on bearing caps. Crankshaft keyway should point upward at 12 o'clock position. Take clear photos of timing mark alignment for reference.
   ⚠️Timing marks MUST be verified before proceeding. Incorrect timing will cause engine damage upon startup.
6. 6

   Remove timing chain guide bolts
   Remove the two guide bolts securing the timing chain guides. The upper guide and lower guide can remain in place but bolts must be removed to access tensioner. Keep guides organized for reinstallation.
7. 7

   Remove old timing chain tensioner
   Remove timing chain tensioner mounting bolt. Carefully extract tensioner assembly from engine block. Note the orientation and position of tensioner for proper replacement installation. Inspect tensioner for wear, scoring, or loss of spring tension.
   ⚠Do not allow timing chain to fall slack. Support chain with wire or zip tie if necessary to maintain position on sprockets.
8. 8

   Prepare and install new tensioner
   Compress new timing chain tensioner plunger fully and insert retaining pin or clip through hole to lock it in compressed position. Install new tensioner into engine block bore, ensuring proper orientation with oil feed hole aligned. Install tensioner bolt and torque to specification.
   ⚠️Tensioner MUST be locked in compressed position with pin installed before mounting. Do not remove pin until instructed.
9. 9

   Reinstall timing chain guides
   Install timing chain guide bolts and torque to specification in sequence. Ensure guides are properly seated against chain and not binding. Verify chain is properly seated on all sprocket teeth with no slack or misalignment.
10. 10

    Release tensioner and verify operation
    Carefully remove retaining pin from timing chain tensioner to allow spring-loaded plunger to extend against chain. Verify tensioner plunger moves smoothly and applies proper pressure to chain. Manually rotate crankshaft two complete revolutions clockwise and recheck all timing marks align perfectly at TDC.
    ⚠️After rotating engine, timing marks must realign exactly. If marks do not align, timing chain position is incorrect and must be corrected before proceeding.
11. 11

    Install timing chain cover with new gasket
    Install new timing cover gasket onto engine block, ensuring all alignment dowels are properly seated. Apply thin bead of Toyota FIPG sealant to specified areas if required per service manual. Install timing cover and hand-start all bolts. Torque 10mm bolts first to 14 Nm, then torque 8mm bolts to 25 Nm in specified sequence pattern (typically center outward).
    ℹ️Proper bolt sequence prevents cover warping. Start at center and work outward in circular pattern.
12. 12

    Install crankshaft pulley
    Clean crankshaft nose and pulley bore thoroughly. Slide pulley onto crankshaft, aligning keyway. Install new crankshaft pulley bolt and torque to 176 Nm using holding tool to prevent rotation. Verify pulley does not wobble or show misalignment.
13. 13

    Reinstall valve cover with new gasket
    Install new valve cover gasket into valve cover groove. Position valve cover onto cylinder head, ensuring gasket seats properly. Install valve cover bolts and torque to 10 Nm in specified sequence (center outward pattern). Reconnect ignition coils and PCV hoses.
14. 14

    Reinstall accessory components
    Reinstall power steering pump and alternator with mounting bolts torqued to specifications. Reinstall accessory drive belt by rotating tensioner and routing belt per diagram on belt routing label. Reinstall right engine mount. Remove engine support jack.
15. 15

    Refill fluids and final checks
    Reinstall oil drain plug with new gasket and refill engine with 5.0 quarts Toyota 0W-20 oil. Refill cooling system with Toyota pink coolant. Reconnect negative battery cable. Start engine and verify no oil leaks at timing cover or valve cover. Listen for abnormal timing chain noise. Allow engine to reach operating temperature and recheck for leaks.
    ⚠If any unusual timing chain noise is heard, immediately shut down engine and reinspect tensioner installation and timing marks.

Reassembly

1. Torque all fasteners to specified values in proper sequence to prevent gasket leaks and ensure proper component alignment
2. Use new gaskets for all removed components including timing cover, valve cover, and drain plug
3. Verify timing marks alignment after rotating engine two complete revolutions before final assembly
4. Double-check that tensioner retaining pin was removed after installation

Verification

• Start engine and listen for smooth, quiet operation with no timing chain rattle or abnormal noises
• Verify no oil leaks from timing cover, valve cover, or crankshaft seal after reaching operating temperature
• Check oil pressure gauge reads normal pressure within 30 seconds of startup
• Test drive vehicle and verify normal acceleration and engine performance with no misfires or rough running
• Recheck oil level after test drive and top off if necessary
• Monitor for any oil consumption or leaks over next 100 miles of driving

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