Timing Belt: Replacement

SEPARATE BATTERY NEGATIVE TERMINAL
REMOVE AIR CLEANER INLET NO. 1
DRAIN ENGINE COOLANT
REMOVE V-BANK COVER
REMOVE INTAKE AIR CONNECTOR PIPE
REMOVE ENGINE UNDER COVER
SEPARATE RADIATOR HOSE NO. 1
SEPARATE RADIATOR HOSE NO. 2
SEPARATE OIL COOLER INLET TUBE NO. 1
SEPARATE OIL COOLER OUTLET TUBE NO. 1
REMOVE AIR CLEANER ASSY
REMOVE RADIATOR ASSY
1. Remove the 2 nuts and 2 upper radiator support.
2. Lift out the radiator and cooling fan assembly.
REMOVE FAN AND GENERATOR V BELT
(See REPLACEMENT )
REMOVE VANE PUMP ASSY
1. Remove the 2 bolts and nut, and the vane pump assembly.
NOTE: Vane pump assembly should be removed with the hoses connected and then hung with a rope or wire in the body's side.
REMOVE GENERATOR ASSY
(See REPLACEMENT )
SEPARATE COMPRESSOR AND MAGNETIC CLUTCH
NOTE: The cooler compressor together with the magnetic clutch should be removed with the low-pressure and high-pressure hoses connected and then hung with a rope or wire in the body's side.
REMOVE TIMING CHAIN OR BELT COVER NO. 2
REMOVE TIMING BELT COVER SUB-ASSY NO. 3 LH
REMOVE TIMING BELT COVER SUB-ASSY NO. 2
REMOVE V-RIBBED BELT TENSIONER ASSY
REMOVE IDLER PULLEY ASSY
REMOVE CRANKSHAFT DAMPER SUB-ASSY
1. Using SST, remove the pulley bolt.
  SST 09213-70011, 09330-00021
  
  Fig 1: Removing Crankshaft Damper Pulley Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the crankshaft pulley.
  SST 09950-50012 (09951-05010, 09952-05010, 09953-05010,09953-05020, 09954-05020)
Fig 2: Removing Crankshaft Pulley
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TIMING BELT NO. 1 COVER
1. Remove the 4 bolts and timing belt cover.
REMOVE CRANKSHAFT POSITION SENSOR PLATE NO. 1
REMOVE TIMING BELT
1. If re-using the timing belt, check the installation marks on the timing belt.
  1. Check that there are 3 installation marks on the timing belt by turning the crankshaft as shown in the illustration.
  If the installation marks have disappeared, place a new installation mark on the timing belt before removing each part.
  
  Fig 3: Identifying Timing Belt Alignment Marks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Set the No. 1 cylinder to approx. 50° BTDC/compression.
  1. Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body.
    
    Fig 4: Aligning Crankshaft Pulley Timing Marks With Oil Pump Body
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Check that the timing marks of the camshaft timing pulleys and timing belt plates aligned.
    If not, turn the crankshaft 1 revolution (360°).
    
    Fig 5: Aligning Camshaft Pulleys With Timing Belt Plate Timing Marks
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Using the crankshaft damper bolt, turn the crankshaft counterclockwise by approx. 50°.
  NOTE: If the timing belt is disengaged, having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you remove the camshaft timing pulley and camshaft, causing damage. So always set the crankshaft pulley at the correct angle.
3. Alternately loosen the 2 bolts, and remove them, the belt tensioner and dust boot.
  
  Fig 6: Turning Crankshaft Counterclockwise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, loosen the tension between the camshaft timing pulley (RH bank) and crankshaft timing pulley by slightly turning the camshaft timing pulley (RH bank) counterclockwise.
  ST09960-10010 (09962-01000, 09963-00350)
  
  Fig 7: Using SST To Release Tension Between Camshaft Timing Pulley (RH Bank) & Crankshaft Timing Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Disconnect the timing belt from the timing belt idler No. 1, and remove the timing belt.
INSTALL TIMING BELT
1. Check the timing belt idler No. 1 and No. 2.
  1. Visually check the seal portion of the idler pulley for oil leakage.
    If leakage is found, replace the idler.
  2. Check that the idler turns smoothly.
    If necessary, replace the idler.
2. Check the water pump.
  1. Visually check the air hole and water hole for coolant leakage.
    If leakage is found, replace the water pump and timing belt.
  2. Turn the pulley, and check that the water pump bearing moves smoothly and quietly.
    If necessary, replace the water pump.
3. Remove any oil or water on the crankshaft pulley, oil pump pulley, water pump pulley, idler No.1 and idler No.2, and keep them clean.
  NOTE: Only wipe the pulleys; do not use any cleansing agent.
  
  Fig 8: Locating Air Hole & Water Hole For Coolant Leakage
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Set the No. 1 cylinder to TDC/compression.
  1. Turn the hexagon wrench head portion of the camshaft to align the timing marks of the camshaft timing pulleys and timing belt plates aligned.
    
    Fig 9: Aligning Camshaft Pulley Timing Marks With Timing Belt Plate
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    NOTE: Setting positions of the camshaft timing pulleys by turning them slightly clockwise makes it easy to install the timing belt:
    
    Camshaft timing pulley of LH bank: 1/2 teeth
    
    Camshaft timing pulley of RH bank: 1 tooth
    
    Fig 10: Turning Camshaft Timing Pulley Clockwise
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body.
    
    Fig 11: Aligning Crankshaft Timing Pulley
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the timing belt.
  1. Remove any oil or water on the each pulley, and keep them clean.
    NOTE: Only wipe the pulleys; do not use any cleansing agent.
  2. Face the front mark (arrow) on the timing belt forward.
  3. Connect the timing belt to the crankshaft timing pulley.
    - Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
    Fig 12: Installing Timing Belt
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Connect the timing belt to the idler No. 2.
  5. Connect the timing belt to the camshaft timing pulley (LH.bank).
    - Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley.
  6. Connect the timing belt to the water pump pulley.
  7. Connect the timing belt to the camshaft timing pulley (RH bank).
    - Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley.
  8. Connect the timing belt to the idler No.1.
6. Set the belt tensioner.
  1. Using a press, slowly press in the push rod using 981 - 9,807 N (100 - 1,000 kgf, 220 - 2,205 lbf) of pressure.
  2. Align the holes of the push rod and housing, pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.
  3. Release the press.
  4. Install the dust boot to the belt tensioner.
  Fig 13: Aligning Push Rod & Housing Holes
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install the belt tensioner.
  1. Temporarily install the belt tensioner with the 2 bolts.
  2. Alternately tighten the 2 bolts.
    Torque: 26 N.m (270 kgf.cm, 19 ft.lbf)
  3. Using pliers, remove the 1.27 mm hexagon wrench from the belt tensioner.
  Fig 14: Removing Hexagon Wrench To Release Belt Tensioner
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Check the valve timing.
  1. Using the crankshaft damper bolt,slowly turn the crankshaft pulley 2 revolutions from TDC to TDC
    NOTE: Always turn the crankshaft pulley clockwise.
    
    Fig 15: Turning Crankshaft Pulley From TDC To TDC
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Check that each pulley aligns with the timing marks as shown in the illustration.
    
    Fig 16: Identifying Aligned Timing Mark
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    If the timing marks do not align, remove the timing belt and reinstall it.
  3. Remove the crankshaft damper bolt.
INSTALL CRANKSHAFT POSITION SENSOR PLATE NO. 1
1. Install the crank angle sensor plate as shown in the illustration.
NOTE: Take care not to install it in the wrong direction.

Fig 17: Installing Crank-Angle-Sensor Plate
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TIMING BELT NO. 1 COVER
1. Install the timing belt cover with the 4 bolts.
  Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf)
INSTALL CRANKSHAFT DAMPER SUB-ASSY
1. Using SST and a hammer, tap in the crankshaft damper.
  SST 09223-46011
  
  Fig 18: Inserting Crankshaft Damper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, install the damper bolt.
  SST 09213-70011, 09330-00021
  
  Fig 19: Installing Damper Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 245 N.m (2,500 kgf.cm, 181 ft.lbf)
3. Align the damper set key with the key groove of the crankshaft damper.
INSTALL IDLER PULLEY ASSY
1. Install the idler with the 2 bolts and 2 nuts.
  Torque:
  
  16 N.m (160 kgf.cm, 12 ft.lbf) for 12 mm head
  
  32 N.m (330 kgf.cm, 24 ft.lbf) for 14 mm head
HINT:

Each bolt length is indicated in the illustration.

Bolt Length:

106 mm (4.17 in.) for 12 mm head (A)

114 mm (4.49 in.) for 14 mm head (B)

Fig 20: Installing Idler Pulley Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL V-RIBBED BELT TENSIONER ASSY
1. Install the belt tensioner with the bolt and 2 nuts.
  Torque: 15.5 N.m (160 kgf.cm, 11 ft.lbf)
NOTE: Use a bolt 106 mm (4.18 in.) in length.
INSTALL TIMING BELT COVER SUB-ASSY NO.2
1. Fit the timing belt cover, matching the claws and pin with each part.
2. Install the timing belt cover with the 2 bolts.
  Torque: 16 N.m (160 kgf.cm, 12 ft.lbf)
NOTE: Use bolts 106 mm (4.17 in.) in length.

Fig 21: Installing Timing Belt Cover Sub Assembly No. 2
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TIMING BELT COVER SUB-ASSY NO. 3 LH
Torque: 7.5 N.m (80 kgf.cm, 66 in. lbf)
INSTALL TIMING CHAIN OR BELT COVER NO. 2
Torque: 7.5 N.m (80 kgf.cm, 66 in. lbf)
INSTALL COMPRESSOR AND MAGNETIC CLUTCH
1. Install the cooler compressor, stay and wire bracket with the 3 bolts and nut.
  Torque:
  
  49 N.m (500 kgf.cm, 36ft.lbf) for bolts
  
  29 N.m (300 kgf.cm, 21 ft.lbf) for nuts
INSTALL GENERATOR ASSY
INSTALL VANE PUMP ASSY
1. Install the vane pump assembly with the 2 bolts and nut. Alternately tighten the bolts and nut.
  Torque:
  
  39.2 N.m (400 kgf.cm, 29 ft.lbf) for bolts
  
  43.1 N.m (440 kgf.cm, 32 ft.lbf) for nuts
INSTALL FAN AND GENERATOR V BELT
(See REPLACEMENT )
INSTALL RADIATOR ASSY
1. Install the radiator and cooling fan assembly with the 2 upper radiator supports and 2 nuts.
  Torque: 13.5 N.m (135 kgf.cm, 10 ft.lbf)
INSTALL AIR CLEANER ASSY
Torque: 5.0 N.m (50 kgf.cm, 41 in. Lbf)
INSTALL AIR CLEANER INLET NO.1
Torque: 5.0 N.m (50 kgf.cm, 41 in. Lbf)
INSTALL INTAKE AIR CONNECTOR PIPE
Torque: 5.0 N.m (50 kgf.cm, 41 in. Lbf)
INSTALL V-BANK COVER
Torque: 5.0 N.m (50 kgf.cm, 41 in. Lbf)
REFILL ENGINE COOLANT (See REPLACEMENT )
CHECK ENGINE COOLANT LEAK (See REPLACEMENT )
INSTALL ENGINE UNDER COVER