Tuesday, May 17, 2011

How to replace timing belt on Toyota highlander 3.3?


Timing Belt & Tensioner


Removal & Installation



3.0L And 3.3L Engines
  1. Before servicing the vehicle, refer to the precautions section.
  2. Remove the right front wheel.
  3. Remove the wiper arms.
  4. Remove the wiper linkage.
  5. Remove the top cowl panel.
  6. Remove the engine undercovers.
  7. Remove the right front fender apron seal.
  8. Remove the A/C compressor drive belt.
  9. Remove the power steering pump belt.
  10. Remove the engine roll control rod.
  11. Remove the right side engine mount stay.
  12. Remove the alternator bracket.
  13. Remove the crankshaft pulley.
  14. Remove the upper belt cover.
  15. Remove the right engine mount bracket.
  16. Remove the no. 2 timing belt guide.
  17. Set the no.1 cylinder to TDC compression.

    Click image to see an enlarged view

    Fig. Check that the timing marks on the camshaft pulleys are aligned with the notches on the inner belt cover

  18. Temporarily install the crank pulley bolt. Turn the crankshaft clockwise to align the timing mark on the crankshaft timing pulley with the notch in the oil pump body. Check that the timing marks on the camshaft pulleys are aligned with the notches on the inner belt cover. If not, rotate the crankshaft 360 degrees clockwise.
    NOTE
    If the timing belt is re-used, check that the 3 original installation marks are visible on the belt as shown. If not, paint three new marks on the belt.



    Click image to see an enlarged view

    Fig. Turn the crankshaft clockwise to align the timing mark on the crankshaft timing pulley with the notch in the oil pump body



    Click image to see an enlarged view

    Fig. If the timing belt is re-used, check that the 3 original installation marks are visible on the belt as shown

  19. Turn the crankshaft counterclockwise by 60 degrees. Make sure that the belt is still engaged.

    Click image to see an enlarged view

    Fig. Turn the crankshaft counterclockwise by 60 degrees

  20. Remove the tensioner.

    Click image to see an enlarged view

    Fig. Remove the belt from the pulleys in this order

  21. Remove the belt from the pulleys in this order:

    Lower idler pulley
    Right camshaft pulley
    Upper idler pulley
    Left camshaft pulley
    Water pump pulley
    Crankshaft timing pulley

  22. If the belt is being re-used, check it for wear or damage; don-t twist it or turn it inside-out. If there is any doubt as to its condition, replace it.

To install:

  1. Clean all the pulleys.
  2. Turn the crankshaft another 60 degrees counterclockwise.
  3. Turn the camshaft pulleys back into alignment so the marks align with the notches on the inner cover.
  4. Turn the crankshaft back so that the timing mark aligns with the notch on the oil pump.

    Click image to see an enlarged view

    Fig. Turn the camshaft pulleys back into alignment so the marks align with the notches on the inner cover

  5. Align the installation marks on the belt with the timing marks on the pulleys.

    Click image to see an enlarged view

    Fig. Install the belt in this order

  6. Install the belt in this order:

    Crankshaft
    Water pump
    Left camshaft
    Upper idler
    Right camshaft
    Lower idler

    Click image to see an enlarged view

    Fig. Set the tensioner in a press and collapse the plunger. Do not apply more that 2,205 lbs (9.8 kN) of force. Insert a suitable metal rod through the holes to hold the plunger in position


  7. Set the tensioner in a press and collapse the plunger. Do not apply more that 2,205 lbs (9.8 kN) of force. Insert a suitable metal rod through the holes to hold the plunger in position.
  8. Install the tensioner and torque the 2 bolts alternately to 20 ft. lbs. (27 Nm).
    WARNING
    Be sure to tighten to bolts alternately and evenly so the tensioner seats flat.

  9. Remove the metal rod from the tensioner.
  10. Turn the crankshaft 2 full revolutions clockwise (720 degrees), and align the timing mark on the crank pulley with the notch on the oil pump.
  11. Check the timing marks on the camshaft pulleys for alignment with the notches on the inner cover. If they do not align, remove the belt and align the mis-matched mark(s).

    Click image to see an enlarged view

    Fig. Install the timing belt guide with the cupped side facing front

  12. The remainder of installation is the reverse of removal. Observe the following torques:

    Right engine mount bracket: 21 ft. lbs. (28 Nm)
    Right engine mount insulator: 70 ft. lbs. (95 Nm)
    Timing belt covers: 75 inch lbs. (8.5 Nm)
    Crankshaft pulley: 159 ft. lbs. (215 Nm) for the 3.0L engine, or to 162 ft. lbs. (220 Nm) for the 3.3L engine
    Alternator bracket: 21 ft. lbs. (28 Nm)
    Right engine mount stay: 47 ft. lbs. (64 Nm)

    Click image to see an enlarged view

    Fig. Tighten the engine roll control rod bolts in this order

    Engine roll control rod: tighten first A, then B, then C to 47 ft. lbs. (64 Nm). Torque D to 17 ft. lbs. (23 Nm)


Hybrid
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove or disconnect the following:

    Negative battery cable
    Engine covers
    Right front wheel
    Fender splash shields
    Wiper arms
    Top cowl ventilator louver
    Wiper motor and linkage assembly
    Battery and battery tray
    Air intake assembly
    Brake master cylinder reservoir and bracket
    Air cleaner bracket
    Engine moving control rod
    Right-hand engine mounting stay No. 2

    Click image to see an enlarged view

    Fig. Remove the right-hand engine mounting stay No. 2


  3. Use Special Tool 09213-54015 to hold the crankshaft pulley in order to loosen the pulley bolt.
  4. Use Special Tool 09950-50013 to remove the crankshaft pulley.

    Click image to see an enlarged view

    Fig. Use the special tool to hold the pulley in order to loosen the pulley bolt



    Click image to see an enlarged view

    Fig. Use the special tool to remove the crankshaft pulley

  5. Remove or disconnect the following:

    Timing belt cover No. 1
    Timing belt cover No. 2
    Right-hand engine mounting bracket
    Timing belt guide No. 2

  6. Temporarily install the crank pulley bolt. Turn the crankshaft clockwise to align the timing mark on the crankshaft timing pulley with the notch in the oil pump body.
  7. Check that the timing marks on the camshaft pulleys are aligned with the notches on the inner belt cover. If not, rotate the crankshaft 360 degrees clockwise.
    NOTE
    If the timing belt is re-used, check that the 3 original installation marks are visible on the belt as shown. If not, paint three new marks on the belt.



    Click image to see an enlarged view

    Fig. Check that the timing marks on the camshaft pulleys are aligned with the notches on the inner belt cover



    Click image to see an enlarged view

    Fig. Turn the crankshaft clockwise to align the timing mark on the crankshaft timing pulley with the notch in the oil pump body



    Click image to see an enlarged view

    Fig. If the timing belt is re-used, check that the 3 original installation marks are visible on the belt as shown

  8. Turn the crankshaft counterclockwise by 60 degrees. Make sure that the belt is still engaged.

    Click image to see an enlarged view

    Fig. Turn the crankshaft counterclockwise by 60 degrees

  9. Remove the timing belt tensioner.

    Click image to see an enlarged view

    Fig. Remove the belt from the pulleys in this order

  10. Remove the belt from the pulleys in this order:

    Lower idler pulley
    Right camshaft pulley
    Upper idler pulley
    Left camshaft pulley
    Water pump pulley
    Crankshaft timing pulley

  11. If the belt is being re-used, check it for wear or damage; don-t twist it or turn it inside-out. If there is any doubt as to it-s condition, replace it.

To install:

  1. Clean all the pulleys.
  2. Turn the crankshaft another 60 degrees counterclockwise.
  3. Turn the camshaft pulleys back into alignment so the marks align with the notches on the inner cover.
  4. Turn the crankshaft back so that the timing mark aligns with the notch on the oil pump.

    Click image to see an enlarged view

    Fig. Turn the camshaft pulleys back into alignment so the marks align with the notches on the inner cover

  5. Align the installation marks on the belt with the timing marks on the pulleys.

    Click image to see an enlarged view

    Fig. Install the belt in this order

  6. Install the belt in this order:

    Crankshaft
    Water pump
    Left camshaft
    Upper idler
    Right camshaft
    Lower idler

  7. Set the tensioner in a press and collapse the plunger. Do not apply more that 2,205 lbs (9.8 kN) of force. Insert a suitable metal rod through the holes to hold the plunger in position.

    Click image to see an enlarged view

    Fig. Set the tensioner in a press and collapse the plunger. Do not apply more that 2,205 lbs (9.8 kN) of force. Insert a suitable metal rod through the holes to hold the plunger in position

  8. Install the tensioner and torque the 2 bolts alternately to 20 ft. lbs. (27 Nm).
    WARNING
    Be sure to tighten to bolts alternately and evenly so the tensioner seats flat.

  9. Remove the metal rod from the tensioner.
  10. Turn the crankshaft 2 full revolutions clockwise (720 degrees), and align the timing mark on the crank pulley with the notch on the oil pump.
  11. Check the timing marks on the camshaft pulleys for alignment with the notches on the inner cover. If they do not align, remove the belt and align the mis-matched mark(s).

    Click image to see an enlarged view

    Fig. Install the timing belt guide with the cupped side facing front

  12. The remainder of installation is the reverse of removal. Observe the following torques:

    Right engine mount bracket: 21 ft. lbs. (28 Nm)
    Right engine mount insulator: 70 ft. lbs. (95 Nm)
    Timing belt covers: 75 inch lbs. (8.5 Nm)
    Crankshaft pulley: 162 ft. lbs. (220 Nm)
    Alternator bracket: 21 ft. lbs. (28 Nm)
    Right engine mount stay: 47 ft. lbs. (64 Nm)
    Engine roll control rod: tighten first A, then B, and then C to 47 ft. lbs. (64 Nm). Torque D to 17 ft. lbs. (23 Nm)

    Click image to see an enlarged view

    Fig. Tighten the engine roll control rod bolts in this order


  13. If necessary, perform the initialization procedure, as outlined in the Chassis Electrical System.

--------------------

Front Crankshaft Seal


Removal & Installation




  1. Before servicing the vehicle, refer to the precautions section.
  2. Remove or disconnect the following:
    NOTE
    To extract the engine bracket and control rod, raise the engine slightly.



    Engine coolant reservoir tank and the alternator belt
    Right front wheel and the splash shield
    Power steering pump drive belt, by loosening both bolts
    Both ground wire connectors
    Right engine mounting stay
    Engine moving control rod and the No. 2 right engine mount bracket



    No. 2 alternator bracket
    Crankshaft pulley bolt, using a prybar and wrench or Crankshaft Pulley Holding tool 09213-54015 and Flange Holding tool 09330-00021
    Crankshaft pulley, using a puller
    No. 1 timing belt cover

  3. Remove the No. 2 timing belt cover, as follows:

    Engine wire protector from the No. 3 (rear) timing belt cover
    Engine wire protector clamp from the No. 3 timing belt cover
    5 bolts from the No. 2 timing belt cover
    No. 2 cover


To install:

  1. Install or connect the following:
    NOTE
    Install it evenly to the part of the belt cover shaded black. After installation, press down on it so that the adhesive sticks to the belt cover firmly.



    No. 2 timing belt cover, using a new gasket



    No. 2 timing belt cover. Tighten the 5 bolts to 74 inch lbs. (8 Nm).
    Engine wire protector clamp to the No. 3 timing belt cover
    Engine wire protector to the No. 3 timing belt cover with the bolt
    No. 3 timing belt cover, using a new gasket
    Tighten the 4 No. 1 timing belt cover bolts to 74 inch lbs. (8 Nm).
    Crankshaft pulley. Tighten the bolt to 159 ft. lbs. (215 Nm).
    No. 2 alternator bracket. Tighten the nut to 21 ft. lbs. (28 Nm). Do not tighten the pivot bolt at this time.
    No. 2 right engine mounting bracket and the moving control rod
    Right engine mount stay
    Both ground wire connectors
    Drive belts by adjusting them
    Coolant reservoir
    Right front splash shield and wheel
    Negative battery cable

  2. Start the vehicle and check for any leaks.
  3. Recheck the ignition timing.

Hybrid
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove the timing belt.
  3. Remove the timing belt plate.
  4. Install the crankshaft pulley bolts to the crankshaft.
  5. Using Special Tool 09950-50013 or equivalent, remove the crankshaft timing pulley.

    Click image to see an enlarged view

    Fig. Using the Special Tool or equivalent puller, remove the crankshaft timing pulley.

  6. Using a knife, cut off the oil seal lip.
  7. Using a suitable pry tool, pry out the oil seal.
    CAUTION
    Use tape on the tip of the pry tool to prevent damage to the crankshaft.


To install:

  1. Apply MP grease to a new oil seal lip.
  2. Using Special Tool 09223-00010 or suitable seal installer and hammer, tap in a new oil seal until its surface is flush with the oil pump edge.
  3. Align the keyway of the crankshaft timing pulley with the key located on the crankshaft and slide the pulley into place.
    NOTE
    Do not scratch the sensor area of the crankshaft timing pulley.

  4. Install the timing belt plate. Tighten to 71 inch lbs. (8 Nm).
  5. Install the timing belt.
  6. If necessary, perform the initialization procedure, as outlined in the Chassis Electrical System.
  7. Start the engine and check for leaks.
---------------

Removal & Installation



3.0L & 3.3L Engines

NOTE
This procedure requires a variety of special tools.

  1. Remove the automatic transaxle assembly (2WD) or automatic transaxle and transfer assembly (4WD), as outlined in the Drive Train Section.
  2. Remove the drive plate and ring gear, as follows:
    1. Secure the crankshaft with Special Service Tool (SST) 09213-54015 (91651-60855), 09330-00021 or their equivalents.

      Click image to see an enlarged view

      Fig. Hold the crankshaft in place with the special tools as shown

    2. Remove the 8 bolts, rear spacer, drive plate and front spacer.

      Click image to see an enlarged view

      Fig. Remove the 8 bolts, rear spacer, drive plate and front spacer


  3. Remove the rear main seal, as follows:
    1. Using a knife, carefully cut off the oil seal lip.
    2. Use a suitable prytool, or taped screwdriver, pry out the oil seal.
      WARNING
      After removing the seal, make sure the crankshaft is not damaged or scratched. If it is, you can mend it with a fine grit (#400) sandpaper.



      Click image to see an enlarged view

      Fig. If using a screwdriver wrapped in tape to remove the rear main seal, be very carefully not to damage the crankshaft



To install:

  1. Install engine rear oil seal, as follows:
    1. Apply suitable grease to a new oil seal lip. Make sure to keep the lip away from foreign materials to avoid picking up contamination or debris.
    2. Using SST 09223-15030, 09950-70010 (09951-07100), or their equivalent, and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. Tap the seal in squarely to make sure it seats properly
      NOTE
      Wipe the extra grease off of the crankshaft.



      Click image to see an enlarged view

      Fig. Use a seal installation tool and hammer to install the rear main seal until its surface is flush with the seal retainer edge


  2. Install drive plate and ring gear, as follows:
    1. Fix the crankshaft with SST 09213-54015 (91651-60855), 09330-00021, or their equivalents.
    2. Clean the bolts and the bolt holes.
    3. Apply a suitable adhesive (part no. 08833-00070, three bond or equivalent) to 2 or 3 threads of the bolt end.
    4. Install and uniformly tighten the 8 bolts, in several passes in the sequence shown in the accompanying illustration to a final torque of 61 ft. lbs. (83 Nm).
      WARNING
      Do not start the engine for AT LEAST one hour after installing the seal!



      Click image to see an enlarged view

      Fig. Drive plate bolt tightening sequence-3.0L and 3.3L engines


  3. Install the automatic transaxle assembly (2WD) or automatic transaxle and transfer assembly (4WD), as outlined in the Drive Train Section.

Hybrid
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove or disconnect the following:

    Transaxle assembly
    Transmission input damper
    Flywheel
    Rear main seal

    Click image to see an enlarged view

    Fig. Cut off the oil seal lip, then pry the seal out of the retaining plate



To install:

  1. Using Special Tool 09223-15030 or equivalent, tap the new seal into place until the surface is flush with the retainer edge.

    Click image to see an enlarged view

    Fig. Tap a new seal into place

  2. Install or connect the following:

    Flywheel
    Transmission input damper
    Transaxle assembly

----------
Water pump removal:----

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Disconnect the negative battery cable.
  3. Drain the engine coolant.
  4. Remove or disconnect the following:

    Right front wheel
    Right fender apron seal
    Accessory drive belts
    Upper engine mount and stay
    Alternator and bracket
    Crankshaft pulley
    Timing belt covers
    Transverse engine mounting bracket
    Timing belt
    Timing belt idler
    Camshaft pulley
    Water pump

  5. Installation is the reverse of removal. Torque the water pump bolts and nuts to 71 inch lbs. (8Nm).

  1. Before servicing the vehicle, refer to the precautions section.
  2. Disconnect the negative battery cable.
  3. Drain the engine coolant.
  4. Remove or disconnect the following:

    Right front wheel
    Right fender apron seal
    Accessory drive belts
    Upper engine mount and stay
    Alternator and bracket
    Crankshaft pulley
    Timing belt covers
    Transverse engine mounting bracket
    Timing belt
    Timing belt idler
    Camshaft pulley
    Water pump

  5. Installation is the reverse of removal. Torque the water pump bolts and nuts to 71 inch lbs. (8 Nm).

Hybrid



  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Drain the engine coolant.
  3. Remove or disconnect the following:

    Negative battery cable
    Engine side covers
    Right-hand front wheel
    Engine splash shield
    Right-hand front fender apron seal
    Wiper arm and blade assembly
    Top cowl ventilator louver assembly
    Wiper motor and link assembly
    Battery and battery tray
    Air intake assembly
    Brake master cylinder reservoir
    Reservoir support bracket
    Air cleaner support bracket
    Engine moving control rod
    Right-hand engine mount
    Crankshaft pulley
    Timing belt cover No.1 and 2
    Timing belt guide
    Timing belt
    Timing belt idler sub-assembly No.1
    Camshaft timing pulley
    Timing belt cover No.3
    Timing belt idler sub-assembly No.2
    Water pump

  4. Installation is the reverse order of removal. Tighten the water pump with a new gasket to 71 inch lbs. (8 Nm).
  5. Refill the coolant to the correct level.
  6. Start the engine and check for leaks.
  7. If necessary, perform the initialization procedure, as outlined in the Chassis Electrical System.
  1. Remove or disconnect the following:

    Alternator
    Water pump pulley
    Water pump

  2. Installation is the reverse of removal. Torque the pump bolts and nuts to 80 inch lbs. (9Nm) and the pulley bolts to 19 ft. lbs. (26Nm).

  1. Before servicing the vehicle, refer to the precautions section.
  2. Disconnect the negative battery cable.
  3. Drain the engine coolant.
  4. Remove or disconnect the following:

    Alternator
    Water pump pulley
    Water pump

    Click image to see an enlarged view

    Fig. Water pump mounting bolts- Highlander



    Click image to see an enlarged view

    Fig. Sealer application- Highlander water pump




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