LS460 - Engine Maintenance & Mishaps

So my plan when getting the car as I do with all cars is to change out all degrading, wear and tear parts so that it is reliable and I don't have worry about things for awhile after it is done. With 155000 miles on the motor I figured it was time to change a couple of parts. 

Belt Tensioner - Dayco (89380)

Idler pulley - Dayco (89537)

Serpentine Belt - Bando (6PK2100)

Water Pump - Aisin (WPT187)

Thermostat - Aisin (THT005)

Coolant recovery tank cap - Gates (31541)

Radiator - Denso (2219223)

Gates Lower radiator hose (23477)

Gates Upper Radiator Hose (23478)

Idler pulley upper- Dayco (89537)

Idler pulley lower - Dayco 89580

Toyota Super Long Life Coolant - 00272SLLC2 x 3

Toyota Valve Cover gaskets - Right - 11213-38030

Toyota Valve Cover gaskets - Left   - 11214-38020

Toyota Spark Plug Gasket (11193-38020) x 8

Toyota Throttle Body Gasket (22271-50050)

NGK Plugs DFH6B-11A

K&N Air Filter 33-2381 x 2

Amsoil Performance improver  APICN (x2)

Amsoil Signature Series 0W-20 oil x 10 qts

Fuel pump spacer gasket (23224-38010 x 2)

Fuel pump insulator (23915-46011 x 2)

O-Ring (90301-A0029 x 4)

Pulsation damper gasket (23279-74010 x 4)

GASKET, CAMSHAFT BEARING CAP OIL HOLE, LH (11159-0P010) X 2

GASKET, CAMSHAFT BEARING CAP OIL HOLE (11159-0S010) X 2

GASKET, CAMSHAFT BEARING CAP OIL HOLE (90430-A0001) X 2

Above was my parts list. The idea was to change the radiator, water pump, pulleys, belts tensioners, all the gaskets involved with valve cover, throttle body, basically anything that I was removing which was a wear and tear item got replaced with new parts and all the old parts got cleaned in the process. The valve cover gasket had a slight leak to it and the fuel pump gasket had a pretty decent amount of oil seepage that I could see, so new valve cover gaskets, fuel pump spacer gasket, insulators, o-rings and spark plug gaskets were in the to do list.

It started off well, removed the radiator support, fans, radiator, water pump etc etc and everything went fairly smoothly, in an hour or so most parts were off. I did spray most of the bolts etc with PB Blaster and all the plastic clips and connectors with WD40 the night before so that it would make things easier to remove and plastic connectors and clips less susceptible to  breaking. These plastic pieces especially are over 12 years old at this point so anything helps.

When it came time to remove the tensioner, the center bolt was seized on there. I tried soaking it etc but it wouldn't budge. I did manage to get the bolt off eventually except and chunk came out with it. Where the bolt is mounted to the timing chain cover stress cracks formed I guess during the process of un-seizing the bolt and by the time I got the bolt out everything had cracked and the cast aluminum cover broke off.

I've checked everywhere for another instance of this happening but I think this is an isolated incident caused more due to user error and lack of experience than anything else.

Well, no point crying over spilt milk so was trying to research what can be done to fix the issue. After some reading there were two options, first was change the timing chain cover or second see if the piece could be welded in. The welding I thought would work because there is no oil pressure behind the cover and also from images of the cover I saw the chain and other parts were a ways away from possible harm due to the heat cause by welding. I thought it was worth a try as opposed to taking off the timing chain cover which would involve removing everything else around it to get to it. Called a buddy of mine to see if that was something that was doable. He said it was worth a try too, so he came the next day with a welder etc to try to fix my mess up. I tried to clean along the cracks etc as best as I could with with a wire brush, and lightly sanded the area and cleaned it off with brake cleaner etc. Well long story short it was not working as planned and we ended up not being able to weld. The oil behind the cover could be to blame for not being able to get any good welds. So we tried and it didn't work. Thanks Danny! Since this was not going to be a weekend project anymore I just had it towed to the shop and asked Danny to fix it.

So in order to change the timing chain cover the alternator, compressor, valve covers, basically everything attached to the cover which is a lot of things, all needed to be removed.

I was traveling out of the country while this was getting done but Danny kept me updated on the progress. With the timing chain cover removed, he sent me a video of the timing chains which had some slack in it. 

Video showing slack

Maybe it was the heat during welding, maybe it just stretched over time. Either way didn't want to just put the cover back on with that being an issue later. Labor to put the chains on while everything is apart anyway is far less than if it needed to be done again later. So another list of parts were ordered

Timing Chaiin Cover Sub-Assy with Oil pump - 11310-38070

Timing Chain Cover Gasket 11328-38030 (X2)

Chain Sub-Assy 13506-38030 (x2)

Chain Sub-Assy, NO.2 13507-31020 (x2)

RH - Damper, Chain Vibration, NO.1 - 13561-38040

LH - Damper, Chain Vibration, NO.1 - 13561-38050

RH - Tensioner Assy, Chain, NO.1 - 13540-0S010

LH - Tensioner Assy, Chain, NO.1 - 13540-0S022

LH - Tensioner Assy, Chain, NO.1 - 13560-0S011

Tensioner Assy, Chain, NO.2 - 13550-0S011

RH - Slipper, Chain Tensioner - 13559-0S030

LH - Slipper, Chain Tensioner - 13559-0S040

Oil pump gasket 15193-0S010

Oil filter housing O-ring - 96722-24030

Front main seal - 90301-A0005

Cam Timing Control Motor O-ring 90301-92004 (x 2)

Timing chain cover O-ring  90301-35006

Water inlet gasket 16325-38020

Water outlet gasket 16341-38030 (x2)

Water inlet housing O-ring 96761-35035 (x2)

The valve covers and other parts were put in the CUDA to get cleaned while they were out.

Everything related to the timing chain was changed. When everything was getting put back together all the other gaskets etc were put in too. 

The new radiator went in as well and with everything put back together she is purring like a kitten with no oil leaks. 

I know it might be excessive but the car is in otherwise good condition and I want to keep it for a long time without any major headaches.Knowing everything was done gives me peace of mind. I want to thank Danny for fixing everything for me the way I would like and dealing with my OCD-Ness. Also Jeremy for letting me use his shop where I tinker with my cars!

-AJ Abraham

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