Toyota Highlander Hybrid 6 2005-06

Timing Belt & Tensioner

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Removal & Installation



3.0L And 3.3L Engines
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove the right front wheel.
  4.  
  5. Remove the wiper arms.
  6.  
  7. Remove the wiper linkage.
  8.  
  9. Remove the top cowl panel.
  10.  
  11. Remove the engine undercovers.
  12.  
  13. Remove the right front fender apron seal.
  14.  
  15. Remove the A/C compressor drive belt.
  16.  
  17. Remove the power steering pump belt.
  18.  
  19. Remove the engine roll control rod.
  20.  
  21. Remove the right side engine mount stay.
  22.  
  23. Remove the alternator bracket.
  24.  
  25. Remove the crankshaft pulley.
  26.  
  27. Remove the upper belt cover.
  28.  
  29. Remove the right engine mount bracket.
  30.  
  31. Remove the no. 2 timing belt guide.
  32.  
  33. 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

  34.  
  35. 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

  36.  
  37. 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

  38.  
  39. Remove the tensioner.

    Click image to see an enlarged view

    Fig. Remove the belt from the pulleys in this order

  40.  
  41. 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
     

  42.  
  43. 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.
  44.  

To install:

  1. Clean all the pulleys.
  2.  
  3. Turn the crankshaft another 60 degrees counterclockwise.
  4.  
  5. Turn the camshaft pulleys back into alignment so the marks align with the notches on the inner cover.
  6.  
  7. 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

  8.  
  9. 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

  10.  
  11. 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

     

  12.  
  13. 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.
  14.  
  15. 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.

  16.  
  17. Remove the metal rod from the tensioner.
  18.  
  19. 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.
  20.  
  21. 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

  22.  
  23. 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)
     

  24.  

Hybrid
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. 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

     

  4.  
  5. Use Special Tool 09213-54015 to hold the crankshaft pulley in order to loosen the pulley bolt.
  6.  
  7. 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

  8.  
  9. 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
     

  10.  
  11. 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.
  12.  
  13. 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

  14.  
  15. 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

  16.  
  17. Remove the timing belt tensioner.

    Click image to see an enlarged view

    Fig. Remove the belt from the pulleys in this order

  18.  
  19. 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
     

  20.  
  21. 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.
  22.  

To install:

  1. Clean all the pulleys.
  2.  
  3. Turn the crankshaft another 60 degrees counterclockwise.
  4.  
  5. Turn the camshaft pulleys back into alignment so the marks align with the notches on the inner cover.
  6.  
  7. 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

  8.  
  9. 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

  10.  
  11. Install the belt in this order:

    Crankshaft
     
    Water pump
     
    Left camshaft
     
    Upper idler
     
    Right camshaft
     
    Lower idler
     

  12.  
  13. 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

  14.  
  15. 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.

  16.  
  17. Remove the metal rod from the tensioner.
  18.  
  19. 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.
  20.  
  21. 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

  22.  
  23. 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

     

  24.  
  25. If necessary, perform the initialization procedure, as outlined in the Chassis Electrical System.
  26.  

 
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