Advice on replacing timing gear case assembly on toyota 1kd-ftv
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Remove old gasket sealant material from timing gear case and engine surfaces, clean
the surfaces before applying a fresh layer of gasket sealant. A build up of old sealant
causes an excess gap between the cover plate and engine which causes the crankshaft and
camshaft sensors to become mislaligned with their respective crank angle sensor plate.
Cleaning the surfaces and applying a fresh layer of gasket sealant creates a proper seal
between the two surfaces. Remove all traces of oil as this will prevent the sealant from
drying and sealing. Let the sealant dry slightly before tighening the bolts to their
torque specification.
A correctly sealed chamber inside the cover prevents oil leaks. It may also be likely that
creating air tight chambers withing compartments like the gear ass, water pump and oil
sump ensure propper operation of their respective oil & water pump. Most liquid pumps
are effective at pumping liquid, when there is an air leak, they are really bad at removing
an air gap to suck through the liquid they require.
Use quality sealant and create good seals on clean, dry brushed surfaces free from oil dirt and
dust. Sometimes it is appropriate to apply non hardening sealant on the threads of the bolts
before they are inserted, leaks can occur through the bolt holes of many cover plates. Most
cover plates are fragile aluminium, don't overtighten bolts or create uneven surfaces. Some
parts of the engines oil circulation are highly pressurised, a toyota gasket kit must be used
instead.
When reinserting the crankshaft and camshaft sensors, ensure they are cleaned and free from
metal particles they attract, ensure they press properly against the timing gear ass cover
surface they connect to. Use cable ties to reconnect their signal wires, don't overtighten
them so the two wires are squeezed against each other.
In Australia the 1kd-ftv crank angle sensor plate for the crankshaft angle sensor is
about 10 degrees away from its keyway marker. The technical diagrams and sensor plates
on most internet sites seem to be selling sensor plates that are 120 degrees away
from their keyway marker. I don't know why, let me know. Ensure you use the correct crankshaft
plate.
Always use a key on the keyways for the crankshaft balancer and camshaft sprocket pulley.
The 1kd-ftv is an interference engine, so the pistons can collide with the valves when
the timing belt is removed.
Don't leave stray keys inside the gear ass, they are small and fall out easily and will get
caught between two sprockets or will interfere with the operation of the sensor plates.
Always tighten the crankshaft pulley really tight, quite often the keyway section is fractured
on the crankshaft and the pulley cracks.
If you have good attention to detail, sometimes it is better to do the job yourself, when you
take the car in to a mechanic, sometimes the job gets passed on to an apprentice and they
rush through it. Taking the gear cover apart requires delicate care and precision.