Tools needed (minimum)
- Metric socket/ratchet set (6–24 mm), extensions, universal joint
- Breaker bar 1/2" drive
- Torque wrench (range to at least 200 Nm)
- Harmonic balancer / crank pulley puller
- Pulley holding tool (or large screwdriver + helper) to prevent crank turning
- Seal driver / suitably sized socket or seal installer
- Engine support bar or jack + wood block (to support engine when removing mount)
- Cam/crank locking pins or timing plate (factory tool set recommended)
- Screwdrivers, pry bars, rubber mallet
- Gasket scraper, wire brush, solvent (brake cleaner)
- Drain pan, funnel, rags
- RTV gasket maker (if specified by OEM) and threadlocker
- Gloves, safety glasses, jack stands, wheel chocks

Safety precautions
- Work on a level surface. Chock rear wheels and use rated jack stands — never rely on a hydraulic jack alone.
- Disconnect negative battery terminal.
- Relieve cooling system pressure before loosening radiator cap; drain coolant into a pan.
- If removing AC lines, have refrigerant recovered by a certified shop — do not vent refrigerant.
- Support the engine when removing engine mounts. Use an engine support bar or floor jack under oil pan with wood block.
- Wear eye protection and gloves; avoid skin contact with solvents and coolant.

Replacement parts commonly required
- Timing cover gasket (or RTV per OEM)
- Front crankshaft oil seal (replace anytime cover removed)
- Camshaft seals (if leaking or high mileage)
- Timing belt/chain components if worn: belt/chain, tensioner, guides/rollers (recommended at belt service interval)
- Crankshaft pulley bolt (inspect — some are torque-to-yield)
- Misc O-rings and small fasteners
- Coolant (if drained) and threadlocker (per manual)

Common pitfalls to avoid
- Not supporting the engine when removing mount — causes misalignment/damage.
- Failing to lock timing positions before removing cover — can cause timing jump, valve/piston interference on interference engines.
- Reusing old crank seal or cover gasket — leads to leaks.
- Damaging crank sealing surface when removing old seal without proper driver.
- Incorrect torque sequence or values — can warp cover or strip threads.
- Contaminating gasket surfaces with oil/coolant; inadequate cleaning.
- Forgetting to replace tensioner/tensioner spring when required.
- Attempting to pull harmonic balancer without proper puller — risk of bending pulley or breaking bolt.

Procedure — step-by-step
(Generalized for Toyota Hilux front timing cover removal/installation. Consult factory manual for model/year-specific details, torque specs, and timing procedures.)

Preparation
1. Park vehicle, chock wheels, set parking brake. Disconnect negative battery terminal.
2. Raise front of vehicle and support securely on jack stands if needed for access to bolt heads. Remove undertray/engine splash shields as required.
3. Drain coolant to below level of area where you will work (drain radiator) if timing cover removal requires coolant outlet removal.

Remove accessories and components blocking cover
4. Remove engine cover, air intake ducting, and any wiring harness clips over timing cover.
5. Loosen and remove serpentine/drive belt using a tensioner tool or breaker bar on the tensioner. Remove belt.
6. Remove accessory brackets, alternator, power steering pump or move aside (do not necessarily disconnect hoses unless required). If AC compressor must be moved, do not discharge system; unbolt and hang with wire.
7. Remove upper timing cover components (valve cover timing chain guards if applicable) to gain access.

Support engine and remove mounts
8. Support engine with an engine support bar or floor jack under oil pan with a block of wood. Remove or loosen the front engine mount(s) that attach to timing cover area if needed. Note mount location and orientation.

Remove crank pulley / harmonic balancer
9. Remove center bolt from crank pulley. Use penetrating oil if required and break with breaker bar. If bolt is tight, use impact gun or a holding tool on pulley to avoid rotating crank.
10. Install harmonic balancer puller onto pulley and extract crank pulley slowly and evenly. Do not pry on pulley lip — use proper puller.

Lock timing and remove cover
11. Rotate engine by turning crank to Top Dead Center (TDC) on No. 1 cylinder according to timing marks. Install cam/crank locking pins/tools to secure timing positions (use OEM tools or equivalent). Confirm marks align.
12. Remove bolts securing timing cover. Keep bolts organized by length/position — some are different lengths.
13. Carefully pry off timing cover. If it’s stuck, use a plastic or wood wedge and avoid gouging mating surfaces.

Inspect and replace components
14. Inspect timing chain/belt, tensioner, guides, sprockets for wear. Replace belt/chain/tensioner as required by condition or service interval.
15. Remove old crank seal from timing cover or block if replacing. Clean mating surfaces thoroughly with scraper and solvent.
16. Install new crank seal with seal driver or appropriate socket sized to seal outer diameter. Press squarely until seat depth equals original or as specified. Do not distort seal lip.
17. Replace timing cover gasket or apply RTV bead as OEM calls out. If cover has an O-ring, replace.

Reinstallation
18. Position timing cover carefully over timing components, ensuring no seals or timing chain guides are displaced. Thread bolts by hand to avoid cross-threading.
19. Torque timing cover bolts to factory specification in recommended sequence.
20. Remove cam/crank locking pins and rotate engine two full revolutions by hand (using breaker bar on crank) and recheck timing marks align. Listen for interference; if engine turns hard, stop and recheck.
21. Reinstall crank pulley and torque pulley bolt to specified torque (consult manual; many crank bolts are very high torque and may require impact tool or torque multiplier). Use threadlocker if specified.
22. Reinstall engine mount(s) and any brackets, alternator, power steering pump, AC compressor, accessories and serpentine belt. Tension belt according to spec.
23. Refill coolant to correct level and bleed cooling system per Toyota procedure.
24. Reconnect battery negative terminal.

Final checks
25. Start engine and run to operating temperature. Check for leaks (oil/coolant) around timing cover and crank seal.
26. Re-torque bolts if required after run-in (consult manual). Reinspect belt tension and accessory alignment.

How key tools are used
- Harmonic balancer puller: bolt puller arms attach to the pulley; a center forcing screw pushes on crank snout to draw pulley off evenly. Use gradual steady pressure. If the crank pulley has a woodruff key or lip, ensure puller arms engage securely.
- Seal driver: a socket matching seals outer diameter or a dedicated driver evenly presses seal into bore; drive squarely until it bottoms. Do not hammer seal lip area directly.
- Cam/crank locking pins: slide into camshaft or crankshaft holes to lock sprockets at TDC. They prevent timing change when cover is removed—always use, or mark positions clearly if factory pins not available.
- Torque wrench: use for all critical fasteners (cover bolts, crank bolt, mounts). Tighten in stages and follow specified sequence.
- Engine support bar or jack: prevents engine sag when mounts removed. Place wood block between jack and oil pan to distribute load.

Notes and recommendations
- Always consult the factory workshop manual for your Hilux’s engine code and year for exact timing lock procedures and torque specs.
- If engine is interference type, do not rotate crank with cam locked by accident — follow proper locking/unalocking sequence.
- Replace timing belt/chain tensioners and guides as preventative measure when cover is off if mileage high.
- Dispose of coolant and old parts per local regulations.

End.
rteeqp73

How to engage 4WD in a Toyota hilux

Can I Put a 4WD Transmission In My 2WD Truck?? Toyota 2WD to 4WD conversions are popular, but I just want to low range of the W56 transmission. So can I swap out the W55 for ...

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