Toyota Highlander Hybrid 6 2005-06

Timing Chain & Sprockets

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Removal & Installation



2.4L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Remove or disconnect the following:

    Hood
     
    Engine oil
     
    Right front wheel
     
    Right fender splash shield
     
    Right fender apron seal
     
    No.1 engine undercover
     
    Engine roll stopper and bracket
     
    Exhaust pipe
     
    Upper engine mount, right side
     
    Accessory drive belts
     
    Alternator
     
    Power steering pump
     

  8.  
  9. Set the No.1 piston at TDC compression.

    Crankshaft pulley
     
    Oil pan
     
    CKP sensor
     
    Chain tensioner assembly No.1
     
    V-belt tensioner
     

  10.  
  11. Take up the weight of the engine with a crane.
  12.  
  13. Remove or disconnect the following:

    Transverse engine mount insulator
     
    Transverse engine mount bracket
     
    Timing chain cover (14 bolts and 2 nuts
     
    CKP sensor plate
     
    Chain tensioner slipper
     
    Primary chain vibration damper
     
    Primary chain and crankshaft sprocket
     

  14.  
  15. Turn the crankshaft 90 degrees counterclockwise and align the adjusting hole of the oil pump drive shaft gear with the groove in the pump.

    Click image to see an enlarged view

    Fig. Aligning the adjusting hole and groove-2.4L Highlander

  16.  
  17. Insert a 4mm diameter bar into the hole to lock the gear in position and remove the nut.
  18.  
  19. Remove the bolt, tensioner plate, spring, tensioner oil pump driveshaft gear and the chain.
  20.  

To install:

  1. Turn the crankshaft so that the key is in the left horizontal position.

    Click image to see an enlarged view

    Fig. Aligning the crankshaft with the key in the left horizontal position-2.4L Highlander

  2.  
  3. Install the secondary chain and gears with the timing marks aligned as shown.

    Click image to see an enlarged view

    Fig. Install the secondary chain and gears with the timing marks aligned as shown-2.4L Highlander

  4.  
  5. Install the damper spring and tensioner plate. Torque the nut to 10 ft. lbs. (13 Nm).
  6.  
  7. Align the oil pump adjusting hole and groove, lock it with the bar and torque the nut to 22 ft. lbs. (30 Nm).
  8.  
  9. Rotate the crankshaft counterclockwise 90 degrees so the crankshaft key is at the 12 o-clock position and shown.

    Click image to see an enlarged view

    Fig. Aligning the crankshaft with the key in the 12 o-clock position-2.4L Highlander

  10.  
  11. Install the primary chain damper. Torque the bolts to 80 inch lbs. (9 Nm).
  12.  
  13. Set the No.1 piston at TDC compression with the timing marks aligned as shown.

    Click image to see an enlarged view

    Fig. Aligning the timing marks with the No.1 piston at TDC compression-2.4L Highlander

  14.  
  15. Turn the crankshaft, using the pulley bolt, until the key is at the 12 o-clock position.
  16.  
  17. Install the bottom end of the chain, with sprocket, so that the colored links are aligned as shown.

    Click image to see an enlarged view

    Fig. Aligning the timing chain bottom end marks-2.4L Highlander

  18.  
  19. Align the upper end timing marks as shown and install the chain.

    Click image to see an enlarged view

    Fig. Aligning the timing chain upper end marks-2.4L Highlander

  20.  
  21. Install the tensioner slipper. Torque the bolt to 14 ft. lbs. (19 Nm).
  22.  
  23. Install the CKP sensor plate with the F mark outwards.
    NOTE
    When installing the cover, use RTV sealant in the positions shown. The cover must be installed within 3 minutes of seal application. Do not start the engine within 2 hours of seal application.

  24.  
  25. Apply the sealant and install the cover. Torque the cover bolts as follows:

    Bolt A: 80 inch lbs. (9 Nm)
     
    Bolts B: 15 ft. lbs. (21 Nm)
     
    Bolts C: 32 ft. lbs. (43 Nm)
     
    Nuts: 80 inch lbs. (9 Nm)

    Click image to see an enlarged view

    Fig. Timing cover sealant application-2.4L Highlander



    Click image to see an enlarged view

    Fig. Timing cover bolt positions-2.4L Highlander

     

  26.  
  27. The remainder of installation is the reverse of removal.
  28.  

 
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