FJ75 3F Timing Gear replacement

[javaman]

Installed the camshaft back into the engine. It's a bit of a pain to line everything up.

When those two markers meet, the Cylinder #6 is at TDC compression. Scratched my head a bit as I thought it would be cylinder #1 until I read the service manual carefully.

TDC Compression in cylinder #1 is obtained when the alignment is as below

 

[javaman]

Clean and install mechanical fuel pump with new gasket

I needed to rotate the crank about 90-180 deg to find where the lever is not compressed by the camshaft

 

[javaman]

Installing the distributor is a bit tricky as it was my first time. The service manual needs to be followed to the letter.

Also there are 2 types - with and without octane selector which has different orientations. Mine was without the selector

Set the cylinder 1 to TDC-Compression. Then rotate the slot below to about 30 deg.

Then following below, the point would rotate left as you drop the distributor.

I made a mistake the first time and missed one worm tooth and hence the ignition was way retarded (you can't see the mark using timing light)

This step is a good indication when the installation is precise. I could not see spark but can hear "tick" when rotating the distributor counterclowise and open the point at the correct moment. It did not happen when I missed the worm gear the first time

 

[javaman]

Install new oil seal for the timing cover.

Considering the effort taken to get to it, I'd only use genuine Toyota

 

[javaman]

I couldn't find the genuine 3F timing cover gasket so bought a generic one.

It seems the same as 2F engine and did fit perfectly

 

[javaman]

Install the timing cover LOOSELY for now so that the seal can be centered on the harmonic balancer

The bolts are of different sizes and the big one needs to be installed using sealant

 

[javaman]

My original harmonic balancer has scored due to age. After some reading I could sleeve that or move the seal back a bit, but couldn't bear the thought of having a leak and need to do this all over again.

So I bought a new balancer "Powerbond" which seems to be quite a popular replacement.

Made in Australia!

 

[javaman]

Torqueing the balancer was easier than I thought! I didn't even need to hold the balancer with any tools.

Just put in 5th gear and engage the handbrake hard.

The specification is to torque to 343Nm however as I put loctite, I torque it to around 324Nm

Proceed with tightening the timing cover bolts afterwards and put back all the belt + ancillaries

 

[javaman]

... and it lives! After some head scratching because I forgot to plug the PCV vacuum




It is a testament of elegance and simplicity of this engine that an untrained person could disassemble half of the engine and make it work!

 

[javaman]

I've fully documented the process here: