Timing Belt: Removal

REMOVE DRIVE BELT TENSIONER ABSORBER 

Remove the 2 nuts and absorber.

1. Remove the 3 bolts, plate washer and pump front bracket.
2. Disconnect the vane pump from the bracket.

Using a 5 mm hexagon wrench, remove the 4 bolts, oil filler cap, timing belt cover and gasket.

Fig 1: Removing No. 3 Timing Belt Cover

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a 5 mm hexagon wrench, remove 3 bolts, timing belt cover and gasket.

Fig 2: Removing No. 2 Timing Belt Cover

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Remove the 3 bolts and tensioner.

Fig 3: Removing Drive Belt Tensioner

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using SST, loosen the pulley bolt.

SST 09213-70011, 09330-00021

Fig 4: Loosening Crankshaft Pulley Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Turn the crankshaft pulley, and align its groove with timing mark "0" of the No. 1 timing belt cover.
   Fig 5: Turning Crankshaft Pulley

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Always turn the crankshaft clockwise.
2. Check that the timing marks (TDC mark) of the camshaft timing pulleys are aligned with the timing marks of the No. 4 timing belt cover.

   If not, turn the crankshaft 1 revolution (360°).

3. Turn the crankshaft pulley 60° counterclockwise to place the sub timing mark (60° mark BTDC) on the crankshaft pulley at the timing mark "0" position of the No. 1 timing belt cover.
   Fig 6: Turning Crankshaft Pulley Counterclockwise

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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 pulleys (steps 13 and 19), thus resulting damage. So, always set the crankshaft pulley at the correct angle.
4. Check that the dot marks (60° mark BTDC) of the camshaft timing pulleys are aligned with the timing marks of the No. 4 timing belt cover.
5. Remove the crankshaft pulley bolt.
   NOTE: Do not turn the crankshaft pulley.
   Fig 7: Removing Crankshaft Pulley Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Re-using timing belt:

Place matchmarks on the timing belt and camshaft timing pulleys as shown in Fig 8 .

Fig 8: Placing Matchmarks On Timing Belt And Camshaft Timing Pulleys

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Alternately loosen the 2 bolts, and remove them, the tensioner and dust boot.
   Fig 9: Removing Tensioner And Dust Boot

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the timing belt from the camshaft timing pulleys.

Using SST, remove the bolt and timing pulley.

SST 09960-10010 (09962-01000, 09963-01000)

Fig 10: Removing Bolt And Timing Pulley Using SST

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Remove the 4 nuts and engine cover.

1. Using a 5 mm hexagon wrench, remove the bolts, and disconnect the engine wire protector from the No. 2 cylinder head cover.
2. Remove the nut, and disconnect the engine wire protector from the intake manifold.
3. Remove the 2 bolts, and disconnect the high-tension cords with the clamp from the No. 2 cylinder head.
   Fig 11: Removing No. 1 Cylinder Head Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 2 nuts from the No. 1 cylinder head cover.
5. Using a torx socket (E5), remove the 2 stud bolts.
   Fig 12: Removing Bolts Using Torx Socket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Remove the 6 bolts, No. 1 cylinder head cover and gasket.

Remove the bolt, union bolt, oil control valve filter and 2 gaskets, and disconnect the No. 1 oil pipe from the No. 3 camshaft bearing cap.

Fig 13: Removing Union Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

• The 5 bolts shown in Fig 14 determine the backlash of the gear in the timing pulley, so do not remove them.

  If any of the 5 bolts are removed, install a new camshaft timing pulley assembly.

• When removing the straight screw plug, follow the prescribed procedure in order to avoid spilling oil on the timing system parts.

Fig 14: Removing VVT-i Pulley (Intake Camshaft Timing) Pulley

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Rotate the VVT-i pulley from left to right 2 to 3 times within its range of movement (30°) and use a waste cloth to collect the oil from the camshaft timing oil control valve installation hole.
   NOTE: Approximately 20 cc (1.2 cu in.) of oil will be ejected, so take care not to spill it.
2. Holding the hexagon portion of camshaft with a wrench.
3. Using a 14 mm hexagon wrench, remove the straight screw plug and seal washer.
   NOTE: Some oil may spill, so put a waster cloth below the plug white doing the operation.
   Fig 15: Removing Straight Screw Plug And Seal Washer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a 10 mm hexagon wrench, and remove the set bolt and VVT-i pulley.
5. Remove the wrench.

Using SST and bolt (diameter: 8 mm, pitch: 1.5 mm), remove the crankshaft pulley.

1. SST 09950-50013 (09951-05010, 09552-05010, 09553-05020, 09554-05031)
2. Bolt: Part No. 90119-18001

Fig 16: Removing Crankshaft Pulley Using SST

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Remove the 5 bolts, timing belt cover and gasket.

HINT:

When re-using timing belt:

Draw an arrow on the timing belt in the direction of engine revolution, and place matchmarks on the timing belt and crankshaft timing pulley.

Fig 17: Drawing Arrow On Timing Belt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a 10 mm hexagon wrench, remove the pivot bolt, plate washer and idler pulley.

Fig 18: Removing Idler Pulley

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and timing belt plate.
2. Remove the crankshaft timing pulley.

   If the pulley cannot be removed by hand, use SST and bolt (diameter: 8 mm, pitch: 1.5 mm) to remove the crankshaft timing pulley.

   1. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05011)
   2. Bolt: Part No. 90119-18001

Fig 19: Removing Crankshaft Timing Pulley

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002