At the 200k miles point, it was nearing time for a refresh of the timing belt and water pump along with all the ancillaries that are on the front end of engine. While the engine was all torn down on the front end it was decided that this would be a good time fix the leaky valve cover gaskets as well.
Being that deep into the engine guts, choosing to replace a lot of the other things for piece of mind was a no-brainer. A new radiator along with a 150 AMP high output alternator for powering the upcoming winch and dual battery were thrown into the mix.
Here's a list, along with part numbers for all parts replaced:
Valve Cover Gasket --
(1) PCV valve - 12204-62010
(1) PCV grommet - 90480-18001
(2) Valve Cover Gaskets (Left/Right) - 11213-62020
(6) Spark Plug Tube Gaskets - 11193-16010
(2) Intake Plenum Gaskets (Upper/Lower) - 17176-62040
(16) Washer Seals (For Valve Cover Bolts) - 90210-05007
(2) Camshaft housing plugs - 11188-62010
(4) 1/2 moon - 11183-62010
(1) Tube of FIPG - 00295-00102 (or -00103)
(1) Oil Filler Cap Gasket - 90430-3714
Timing Belt and Water Pump --
(1) Timing Belt - 13568-YZZ03
(1) Idler Roller - 13503-62040
(1) Tensioner Roller - 13505-62070
(1) Front Crankshaft Seal - 90311-40022
(2) Front Camshaft Seals - 90311-38051
(1) Water Pump - 16100-69398-83
(1) Water Pump Gasket - 16271-62011
(1) Hydraulic Tensioner - 13540-62021
(1) Thermostat (82°c) - 90916-03075
(1) Thermostat Gasket - 16325-62010
(1) Air Conditioning Belt - 99364-20870
(1) Alternator Belt - 90080-91090
(1) Power Steering Belt - 90080-91126
(1) Radiator Upper Hose - 16571-07030
(1) Radiator Lower Hose - 16572-62070
(1) Crankshaft Pulley Bolt - 90119-16006
(1) Oil Cooler Hose #1 - 15778-62030
(1) Oil Cooler Hose #2 - 15777-62020
(1) Water Inlet - 16321-62020
(1) A/T Radiator - 16400-75180 (Manual Trans: A/M Radiator 16400-75160)
(1) Dip Stick O-ring - 96721-19010
(1) Upper Timing Cover Gasket - 11329-20010
(1) Lower Timing Cover Gasket - 11328-20020
I personally would recommend the Ebay kit from Ebay user aircabinman. He's got varying versions from economical OEM/3rd party essential parts replacement all the way to full OEM all inclusive kits. The OEM kits include verifiably genuine OEM Toyota parts. Additional parts were added to the kits for replacing addition items like the radiator hoses and the dip-stick o-ring.
Taking your time and having the right tools makes the this job go quickly. In addition to your standard metric socket set and wrenches (ratcheting are the best), it is handy to have some long handled pliers and lots of rags to wipe up messes. Here is a list of a couple of other tools that were acquired or made specially for this job to make things easier:
Lisle 58430 Shaft Type Seal Puller
4-5 feet of 1/4" steel bar (for crank/cam pulley holder)
2 x M8-1.25 bolts 2-3" long
It was going to be fun cleaning up the engine bay:
The driver's side cam pulley was really on there tight:
First attempt removing it bent my original 3/8" steel bar crank/cam pulley holder:
Be careful removing the crank pulley, as it is heavy and hard to control if you try to just rip it out. I'll have to replace the A/C condenser at some point now, but there aren't any leaks at least:
Top of the cams look really good for 200k miles:
drivers side -
passengers side:
After checking all the valves for clearances, everything was within spec:
Factor Specifications -
Intake: 0.13 to 0.23mm
Exhaust: 0.27 to 0.37mm
Cylinder 1 intake: front 0.15mm - rear 0.18mm
Cylinder 1 exhaust: front 0.35mm - rear 0.35mm
Cylinder 3 intake: front 0.20mm - rear 0.18mm
Cylinder 3 exhause: front 0.30mm - rear 0.30mm
Cylinder 5 intake: front 0.18mm - rear 0.18mm
Cylinder 5 exhaust: front 0.33mm - rear 0.35mm
Cylinder 2 intake: front 0.23mm - rear 0.18mm
Cylinder 2 exhaust: front 0.28mm - rear 0.30mm
Cylinder 4 intake: front 0.18mm - rear 0.18mm
Cylinder 4 exhaust: front 0.35mm - rear 0.30mm
Cylinder 6 intake: front 0.18mm - rear 0.22mm
Cylinder 6 exhaust: front 0.35mm - rear 0.35mm
Everything torn down:
Choosing to take the time to clean up all the parts was a good idea, as they were dirty:
All cleaned up and put back together: