Toyota Tundra 2001-06

Timing Belt, Cover & Seal

Print

Removal & Installation



3.4L Engine
  1. Disconnect the negative battery cable.
    CAUTION
    Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative battery cable is disconnected.

  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the engine undercover.
  6.  
  7. Drain the engine coolant.
  8.  
  9. Disconnect the upper radiator hose from the engine.
  10.  
  11. Remove the power steering drive belt.
  12.  
  13. Remove the air conditioning drive belt by loosening the idler pulley nut and the adjusting bolt.
  14.  
  15. Loosen the lockbolt, pivot bolt, and the adjusting bolt and the alternator drive belt.
  16.  
  17. Remove the No. 2 fan shroud by removing the 2 clips.
  18.  
  19. Remove the fan with the fluid coupling and fan pulleys.
  20.  
  21. Disconnect the power steering pump from the engine and set aside. Do not disconnect the lines from the pump.
  22.  
  23. If equipped with air conditioning, disconnect the compressor from the engine and set aside. Do not disconnect the lines from the compressor.
  24.  
  25. If equipped with air conditioning, disconnect the air conditioning bracket.
  26.  
  27. Remove the No. 2 timing belt cover, as follows:
    1. Detach the camshaft position sensor connector from the No. 2 timing belt cover.
    2.  
    3. Disconnect the 3 spark plug wire clamps from the No. 2 timing belt cover.
    4.  
    5. Remove the 6 bolts and remove the timing belt cover.
    6.  

  28.  
  29. Remove the fan bracket, as follows:
    1. Remove the power steering adjusting strut by removing the nut.
    2.  
    3. Remove the fan bracket by removing the bolt and nut.
    4.  

  30.  
  31. Set the No. 1 cylinder at Top Dead Center (TDC) of the compression stroke, as follows:
    1. Turn the crankshaft pulley and align its groove with the timing mark 0 of the No. 1 timing belt cover.
    2.  
    3. Check that the timing marks of the camshaft timing pulleys and the No. 3 timing belt cover are aligned. If not, turn the crankshaft pulley one revolution (360 degrees).
      NOTE
      If reusing the timing belt, be sure that you can still read the installation marks. If not, place new installation marks on the timing belt to match the timing marks of the camshaft timing pulleys.

    4.  

  32.  
  33. Remove the timing belt tensioner by alternately loosening the 2 bolts.
  34.  
  35. Remove the camshaft timing pulleys, as follows:
    1. Using SST 09960-10010, or equivalent, remove the pulley bolt, the timing pulley and the knock pin. Remove the 2 timing pulleys with the timing belt.
    2.  

  36.  
  37. Remove the crankshaft pulley, as follows:
    1. Using SST 09213-54015 and 09330-00021 or their equivalents, loosen the pulley bolt.
    2.  
    3. Remove the SST tool, the pulley bolt and the pulley.
    4.  

  38.  
  39. Remove the starter wire bracket and the No. 1 timing belt cover.
  40.  
  41. Remove the timing belt guide and remove the timing belt.
  42.  
  43. Remove the bolt and the No. 2 idler pulley.
  44.  
  45. Remove the pivot bolt, the No. 1 idler pulley and the plate washer.
  46.  
  47. Remove the crankshaft gear.

    Click image to see an enlarged view

    Fig. Turn the crankshaft clockwise to align the timing marks before removing the timing belt-3.4L engine

  48.  

To install:

  1. Install the crankshaft timing gear.
    1. Align the timing pulley set key with the key groove of the gear.
    2.  
    3. Using SST 09214-60010, or equivalent, and a hammer, tap in the timing gear with the flange side facing inward.
    4.  

  2.  
  3. Install the plate washer and the No. 1 idler pulley with the pivot bolt and tighten it to 26 ft. lbs. (35 Nm). Check that the pulley bracket moves smoothly.
  4.  
  5. Install the No. 2 timing belt idler with the bolt. Tighten the bolt to 30 ft. lbs. (40 Nm). Check that the pulley bracket moves smoothly.
  6.  
  7. Temporarily install the timing belt, as follows:
    1. Using the crankshaft pulley bolt, turn the crankshaft and align the timing marks of the crankshaft timing pulley and the oil pump body.
    2.  
    3. Align the installation mark on the timing belt with the dot mark of the crankshaft timing pulley.
    4.  
    5. Install the timing belt on the crankshaft timing pulley, No. 1 idler pulley and the water pump pulleys.
    6.  

  8.  
  9. Install the timing belt guide with the cup side facing outward.
  10.  
  11. Install the No. 1 timing belt cover and starter wire bracket. Tighten the timing belt cover bolts to 80 inch lbs. (9 Nm).
    WARNING
    If any binding is felt when adjusting the timing belt tension by turning the crankshaft, STOP turning the engine, because the pistons may be hitting the valves.

  12.  
  13. Install the crankshaft pulley, as follows:
    1. Align the pulley set key with the key groove of the crankshaft pulley.
    2.  
    3. Install the pulley bolt and tighten it to 184 ft. lbs. (250 Nm).
    4.  

  14.  
  15. Install the left camshaft timing pulley.
    1. Install the knock pin to the camshaft.
    2.  
    3. Align the knock pin hose of the camshaft with the knock pin groove of the timing pulley.
    4.  
    5. Slide the timing belt pulley on the camshaft with the flange side facing outward. Tighten the pulley bolt to 81 ft. lbs. (110 Nm).
    6.  

  16.  
  17. Set the No. 1 cylinder to TDC of the compression stroke, as follows:
    1. Turn the crankshaft pulley, and align its groove with the timing mark 0 of the No. 1 timing belt cover.
    2.  
    3. Turn the camshaft to align the knock pin hole of the camshaft with the timing mark of the No. 3 timing belt cover.
    4.  
    5. Turn the camshaft timing pulley, and align the timing marks of the camshaft timing pulley and the No. 3 timing belt cover.
    6.  

  18.  
  19. Connect the timing belt to the left camshaft timing pulley, as follows:
    NOTE
    Check that the installation mark on the timing belt is aligned with the end of the No. 1 timing belt cover.

    1. Using SST 09960-01000, or equivalent, slightly turn the left camshaft timing pulley clockwise. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley and hang the timing belt on the left camshaft timing pulley.
    2.  
    3. Align the timing marks of the left camshaft pulley and the No. 3 timing belt cover.
    4.  
    5. Check that the timing belt has tension between the crankshaft timing pulley and the left camshaft timing pulley.
    6.  

  20.  
  21. Install the right camshaft timing pulley and the timing belt, as follows:
    1. Align the installation mark on the timing belt with the timing mark of the right camshaft timing pulley and hang the timing belt on the right camshaft timing pulley with the flange side facing inward.
    2.  
    3. Slide the right camshaft timing pulley on the camshaft. Align the timing marks on the right camshaft timing pulley and the No. 3 timing belt cover.
    4.  
    5. Align the knock pin hole of the camshaft with the knock pin groove of the pulley and install the knock pin. Install the bolt and tighten it to 81 ft. lbs. (110 Nm).
    6.  

  22.  
  23. Set the timing belt tensioner, as follows:
    1. Using a press, slowly press in the pushrod using 220-2205 lbs. (981-9807 N) of force.
    2.  
    3. Align the holes of the pushrod and housing, pass a 1.5mm hex wrench through the holes to keep the setting position of the pushrod.
    4.  
    5. Release the press and install the dust boot on the tensioner.
    6.  

  24.  
  25. Install the timing belt tensioner and alternately tighten the bolts to 20 ft. lbs. (28 Nm). Using pliers, remove the 1.5mm hex wrench from the belt tensioner.
  26.  
  27. Check the valve timing, as follows:
    1. Slowly turn the crankshaft pulley 2 revolutions from TDC to TDC. Always turn the crankshaft pulley clockwise.
    2.  
    3. Check that each pulley aligns with the timing marks. If the timing marks do not align, remove the timing belt and reinstall it.
    4.  

  28.  
  29. Install the fan bracket with the bolt and nut.
  30.  
  31. Install the power steering adjusting strut with the nut.
  32.  
  33. Install the No. 2 timing belt cover. Tighten the bolts to 80 inch lbs. (9 Nm). Install the remaining components.
  34.  
  35. Fill the cooling system with coolant.
  36.  
  37. Connect the negative battery cable.
  38.  
  39. Start the engine and check for leaks.
  40.  

4.7L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the oil pan protector and the engine under cover.
  6.  
  7. Drain the cooling system.
  8.  
  9. Lower the vehicle and remove the battery clamp cover.
  10.  
  11. From the top of the engine, remove the fuel return hose, the engine cover nuts/bolts and the cover.
  12.  
  13. Remove the air cleaner and the intake air connector assembly.
  14.  
  15. Remove the cooling fan pulley by performing the following procedures:
    1. Loosen the 4 fan clutch-to-fan pulley nuts.
    2.  
    3. Using a box-end wrench on the serpentine drive belt tensioner bolt, rotate the tensioner counterclockwise and remove the drive belt.
      NOTE
      The serpentine drive belt tensioner bolt is a left-hand thread.

    4.  
    5. Remove the fan clutch-to-fan pulley nuts, the fan, the clutch assembly and the fan pulley.
    6.  

  16.  
  17. Remove the radiator by performing the following procedures:
    1. Disconnect the upper, lower and reservoir hoses from the radiator.
    2.  
    3. Disconnect and plug the automatic transmission oil cooler at the radiator. Disconnect the automatic transmission oil cooler hoses from the fan shroud clamp.
    4.  
    5. Remove the radiator reservoir tank.
    6.  
    7. Remove the fan shroud-to-radiator bolts and the shroud.
    8.  
    9. Remove the 2 upper radiator-to-chassis nuts.
    10.  
    11. Remove the middle radiator-to-chassis nut/bolts and brackets.
    12.  
    13. Carefully, lift the radiator from the vehicle.
    14.  

  18.  
  19. Remove the power steering pump.
  20.  
  21. Remove the serpentine drive belt idler pulley bolt, cover plate and pulley.
  22.  
  23. Remove the right side (No. 3) timing belt cover.
  24.  
  25. Remove the left side (No. 3) timing belt cover by performing the following procedures:
    1. Disconnect the engine wire from both wire clamps.
    2.  
    3. Disconnect the camshaft position sensor wire from the wire clamp on the left-side (No.3) timing belt cover.
    4.  
    5. Disconnect the sensor connector from the connector bracket.
    6.  
    7. Disconnect the sensor connector.
    8.  
    9. Remove the wire grommet from the left-side (No. 3) timing belt cover.
    10.  
    11. Remove the oil cooler tube bolts and tube.
    12.  

  26.  
  27. Remove the middle (No. 2) timing belt cover bolts and cover.
  28.  
  29. Remove the air conditioning compressor and position it to the side.
  30.  
  31. Remove the cooling fan bracket nuts/bolts and bracket.
    NOTE
    If reusing the timing belt, make sure that there are 3 installation marks on the belt; if there are none, install them.

  32.  
  33. Using the Crankshaft Pulley Holding tool 09213-70010, Bolt tool 90105-08076 and Companion Flange Holding tool 09330-00021, or equivalent, loosen the crankshaft pulley bolt.
  34.  
  35. Position the No. 1 cylinder to approximately 50 degrees After Top Dead Center (ATDC) of the compression stroke by performing the following procedures:
    1. Rotate the crankshaft pulley (CLOCKWISE) to align its groove with the timing mark -0- on the lower (No. 1) timing belt cover.
    2.  
    3. Check that the camshaft sprocket timing marks are aligned with the rear timing belt plate marks; if not, rotate the crankshaft 1 revolution (360 degrees).
    4.  
    5. Rotate the crankshaft pulley approximately 50 degrees (CLOCKWISE) and align the crankshaft pulley timing mark between the centers of the crankshaft pulley bolt and the idler pulley bolt.
      WARNING
      If the timing belt is disengaged, having the crankshaft pulley in the wrong angle can cause the valve to come into contact with the piston when removing the camshaft pulley.

    6.  

  36.  
  37. Remove the crankshaft pulley bolt.
    NOTE
    If reusing the timing belt and the installation marks have disappeared, place new installation marks on the timing belt to match the camshaft timing sprocket marks.


    NOTE
    To avoid meshing the timing sprocket and the timing belt, secure one with a string; then, place matchmarks on the timing belt and the right-side camshaft timing sprocket.

  38.  
  39. Remove the timing belt tensioner bolts and the tensioner.
  40.  
  41. Using the Camshaft Holding tool 09960-10010, or equivalent, slightly turn the left-side camshaft sprocket clockwise to loosen the tension spring. Then, disconnect the timing belt from the camshaft sprockets.
  42.  
  43. Remove the alternator by performing the following procedures:
    1. Disconnect the electrical connector from the alternator.
    2.  
    3. Remove the rubber cap/nut and disconnect the battery wire from the alternator.
    4.  
    5. Disconnect the wire clamp from the alternator cord clip.
    6.  
    7. Remove the alternator-to-engine nuts/bolts and the alternator.
    8.  

  44.  
  45. Remove the serpentine drive belt tensioner nuts/bolts and the tensioner.
  46.  
  47. Using the Crankshaft Puller Assembly tool 09950-50012, or equivalent, press the crankshaft pulley from the crankshaft.
    WARNING
    DO NOT rotate the crankshaft pulley.

  48.  
  49. Remove the lower (No. 1) timing belt cover bolts and the cover.
  50.  
  51. Remove the timing belt guide, spacer and the timing belt.

    Click image to see an enlarged view

    Fig. Upper timing belt and related components-4.7L engine



    Click image to see an enlarged view

    Fig. Upper timing sprockets and related components-4.7L engine



    Click image to see an enlarged view

    Fig. Lower timing belt and related components-4.7L engine



    Click image to see an enlarged view

    Fig. Timing belt and sprocket alignment-4.7L engine



    Click image to see an enlarged view

    Fig. Aligning of crankshaft pulley timing mark with the center line of the crankshaft pulley bolt and the idler pulley bolt-4.7L engine



    Click image to see an enlarged view

    Fig. Securing the timing belt with string and matchmarking the camshaft with the timing belt-4.7L engine



    Click image to see an enlarged view

    Fig. Installing the timing belt on the crankshaft sprocket-4.7L engine



    Click image to see an enlarged view

    Fig. Securing the timing belt tensioner pushrod-4.7L engine



    Click image to see an enlarged view

    Fig. Checking the TDC alignment marks after rotating the crankshaft 2 revolutions-4.7L engine

  52.  

To install:


NOTE
With the timing belt removed, this is a perfect opportunity to inspect and/or replace the water pump.

  1. Inspect the timing belt tensioner by performing the following procedures:
    1. Inspect the seal for leakage; if leakage is suspected, replace the tensioner.
    2.  
    3. Using both hands to hold the tensioner facing upward, strongly press the pushrod against a solid surface. If the pushrod moves, replace the tensioner.
      WARNING
      Never hold the tensioner with the pushrod facing downward.

    4.  
    5. Measure the pushrod protrusion from the housing end, it should be 0.413-0.453 in. (10.5-11.5mm). If the protrusion is not as specified, replace the tensioner.
    6.  

  2.  
  3. Temporarily install the timing belt by performing the following procedures:
    1. Align the timing belt-s installation mark with the crankshaft timing sprocket.
    2.  
    3. Install the timing belt on the crankshaft timing sprocket, the No. 1 idler pulley and the No. 2 idler pulley.
    4.  

  4.  
  5. Install the gasket to the timing belt cover spacer and install the cover spacer.
  6.  
  7. Install the timing belt guide with the cup side facing outward.
  8.  
  9. Install the lower (No. 1) timing belt cover.
  10.  
  11. Install the crankshaft pulley by performing the following procedures:
    1. Align the crankshaft pulley with the crankshaft key.
    2.  
    3. Using the Crankshaft Installer tool 09223-46011, or equivalent, and a hammer, tap the crankshaft pulley into position.
    4.  

  12.  
  13. Install the serpentine drive belt tensioner and torque the tensioner-to-engine bolts to 12 ft. lbs. (16 Nm) for 2001-2004 vehicles and 19 ft. lbs. (26 Nm) for 2005-2006 vehicles.
    NOTE
    To install the serpentine drive belt tensioner, use a bolt 4.18 in. (106mm) in length.

  14.  
  15. Check that the crankshaft pulley-s timing mark is aligned with the centers of the idler pulley and crankshaft pulley bolts.
  16.  
  17. Install the alternator and torque the alternator-to-engine nuts/bolts to 29 ft. lbs. (39 Nm). Connect the alternator-s electrical connectors and clip.
  18.  
  19. Install the timing belt to the left-side camshaft by performing the following procedures:
    1. Rotate the left-side camshaft pulley to align the timing belt installation mark with the camshaft sprocket-s timing mark and slide the belt onto the camshaft timing sprocket.
    2.  
    3. Using the Camshaft Holding tool 09960-10010, or equivalent, slightly turn the left-side camshaft sprocket counterclockwise to place tension on the timing belt between the crankshaft sprocket and the camshaft sprocket.
    4.  

  20.  
  21. Rotate the right-side camshaft pulley to align the timing belt installation mark with the camshaft sprocket-s timing mark and slide the belt onto the camshaft timing sprocket.
  22.  
  23. Using a vertical press, slowly press the pushrod into the housing using 200-2205 lbs. (981-9807 N) until the holes align, then, install a 1.27mm Allen® wrench to secure the pushrod and release the press. Install the dust boot on the tensioner housing.
  24.  
  25. Install the timing belt tensioner and torque the bolts to 19 ft. lbs. (26 Nm).
  26.  
  27. Using a pair of pliers, remove the Allen® wrench from the tensioner housing.
  28.  
  29. Check the valve timing by performing the following procedure:
    1. Temporarily install the crankshaft pulley bolt.
    2.  
    3. Slowly, rotate the crankshaft pulley 2 revolutions (CLOCKWISE) and realign the TDC marks.
      NOTE
      If the pulley/sprocket timing marks do not realign, remove the timing belt and reinstall it.

    4.  

  30.  
  31. Using the Crankshaft Pulley Holding tool 09213-70010, Bolt tool 90105-08076 and Companion Flange Holding tool 09330-00021, or equivalent, torque the crankshaft pulley bolt to 181 ft. lbs. (245 Nm).
  32.  
  33. Install the cooling fan bracket and torque the 12mm (head size) bolt to 12 ft. lbs. (16 Nm) and the 14mm (head size) bolt to 24 ft. lbs. (32 Nm).
  34.  
  35. Install the air conditioning compressor.
  36.  
  37. Install the middle (No. 2) timing belt cover and torque the bolts to 12 ft. lbs. (16 Nm).
  38.  
  39. Install the upper right-side (No. 3) timing belt cover and torque the bolts to 66 inch lbs. (7.5 Nm).
  40.  
  41. Install the upper left-side (No. 3) timing belt cover by performing the following procedures:
    1. Install the oil cooler tube and bolt.
    2.  
    3. Feed the Camshaft Position Sensor (CPS) through the left-side (No. 3) timing belt cover hole.
    4.  
    5. Install the left-side (No. 3) timing belt cover and torque the bolts to 66 inch lbs. (7.5 Nm).
    6.  
    7. Install the wire grommet to the left-side (No. 3) timing belt cover.
    8.  
    9. Install the sensor connector to the connector bracket and connect the sensor connector.
    10.  
    11. Install the sensor wire and the engine wire to the clamps on the left-side (No. 3) timing belt cover.
    12.  

  42.  
  43. Install the drive belt idler pulley and cover plate; then, torque the pulley bolt to 27 ft. lbs. (37 Nm) on 2001-2004 vehicles and to 29 ft. lbs. (39 Nm) on 2005-2006 vehicles.
  44.  
  45. To complete the installation, reverse the removal procedures.
  46.  
  47. Refill the cooling system and connect the negative battery cable.
  48.  

 
label.common.footer.alt.autozoneLogo