Toyota 13568-YZZ03
Timing Belt

The first step to remove the timing belt requires removal of the engine under cover followed by draining engine coolant before disconnecting the upper radiator hose. Professionals should disconnect the PS pump by taking off two PS air hoses from both the air intake chamber and resonator while also unfastening the PS pressure tube frame clamp bolt and drive belt together with the PS pump bolt and nut. You must first disconnect the A/C compressor from the engine through removing its connector and drive belt and four bolts. The servicing engineer starts by opening the fan with fluid coupling and fan pulleys while removing the generator drive belt followed by the No.2 fan shroud and fan with fluid coupling and fan pulleys and finally the A/C compressor bracket using five bolts. Start by removing the oil dipstick guide then detach the No.2 timing belt cover through disconnecting four high-tension cord clamps and six bolts and disconnecting the camshaft position sensor connector. The PS pump adjusting strut needs removal while unscrewing its associated nut to access the fan bracket with its bolt and nut. The crankshaft pulley removal sequence starts with bolt loosening using Special Service Tool: 09213-54015 (90119-08216) 09330-00021 followed by removal of Special Service Tool: 09950-50011 (09951-05010, 09952-05010, 09953-05020, 09954-05031). Additional steps include using the tool to remove pulley bolt along with pulley. Two bolts must be removed from the starter wire bracket while four bolts need removal from the No.1 timing belt cover to proceed. Place the crankshaft pulley bolt temporarily to set the first cylinder at maximum compression point while checking for correct timing mark alignment between camshaft pulleys and the third timing belt cover. A careful examination should be done for the three installation marks and front mark on the timing belt. The addition of new marks will be necessary if any of those marks are missing during removal. Begin removing the timing belt tensioner by alternating the bolt looseness on two points before removing the timing belt. Use Special Service Tool: 09960-10010 (09962-01000, 09963-01000) to loosen the camshaft timing pulley bolt before you take off the bolt and knock pin along with the timing pulley for the RH side. Follow the same procedure for the LH camshaft timing pulley. Numerous steps follow for pulley removal where you need to first remove bolt from the No.2 idler pulley and secondly use 10 mm hexagon wrench to detach the pivot bolt and plate washer from the No.1 idler pulley. Start by removing the crankshaft timing pulley through the use of Special Service Tool: 09950-50011 (09951-05010, 09953-05020, 09954-05031) that includes a service bolt when needed. Check the timing belt for damages and bend and twist while verifying it does not touch oil, water or steam. Confirm it is installed correctly and look for signs of normal wear. The inspection of idler pulleys must include an evaluation for oil leakage and smooth operation while the timing belt tensioner needs evaluation for oil leakage along with proper push rod functionality. The crankshaft timing pulley should be installed with the set key in the groove followed by installation of the No.1 idler pulley at 35 Nm (350 kgf-cm, 26 ft. lbs.) and No.2 idler pulley at 40 Nm (400 kgf-cm, 30 ft. lbs.). The LH and RH camshaft timing pulleys need installation with the flange outside and Special Service Tool: 09960-10010 (09962-01000, 09963-01000) to tighten the pulley bolts to 110 Nm (1,100 kgf-cm, 81 ft. lbs.). Align the timing belt between its marks after cleaning before placing the belt at No.1 cylinder TDC. Press the push rod to adjust the timing belt tensioner and fasten it with a 1.27 mm hexagon wrench. Secure the tensioner using two bolts which should be tightened to 27 Nm (280 kgf-cm; 20 ft. lbs.). Adjust the valve timing by matching timing marks before installing the timing belt guide and No.1 timing belt cover and starter wire bracket while checking gasket conditions. Use Special Service Tool 09213-54015 (90119-08216), 09330-00021 to install the crankshaft pulley with a newly installed bolt that requires a torque of 295 Nm (3,000 kgf-cm, 217 ft. lbs.). The technician installs the fan bracket along with the A/C compressor bracket before fixing the fan with fluid coupling and fan pulleys as a temporary operation. Install the Number 2 fan shroud before adjusting generator drive belt tension while tightening the fan with coupling and pulleys to 5.4 Nm (54 kgf-cm, 48 inch lbs.). Then secure the A/C compressor to the engine using four bolts tightened to 25 Nm (250 kgf-cm, 18 ft. lbs.) and connect the PS pump to the engine with 43 Nm (440 kgf-cm, 31 ft. lbs. torque). After connecting the upper radiator hose you should add coolant to the engine then start it to search for leaks during the procedure followed by engine under cover installation and a road test to check abnormal noise or operation before rechecking the engine coolant level.

Beginning the timing belt replacement requires removal of the under engine cover and draining engine coolant followed by upper radiator hose separation. The PS pump requires disconnect from the engine through the removal of two PS air hoses from both air intake chamber and resonator as well as the frame-mounted PS pressure tube bolt and drive belt and bolt-and-nut combination to detach the PS pump. The A/C compressor requires disconnection from the engine using three procedures which include removing the drive belt along with the A/C compressor connector and four bolts. Begin the process by loosening the fan and its fluid coupling system along with the fan pulleys and then remove the generator drive belt. After which remove the No.2 fan shroud as well as the fan controlled by a fluid coupling and its pulleys and finally the A/C compressor bracket through the use of five bolts. You should remove all parts of the oil dipstick system which include the bolt along with the dipstick and guide as well as the O-ring. To begin the camshaft position sensor connector needs disconnecting while four high-tension cord clamps must be removed and six bolts must be unfastened from the No.2 timing belt cover. Unscrew the multivariable pump adjusting strut and its attached PS pump strut nut before removing the bolt and fan bracket together with the nut. To loosen the crankshaft pulley bolt first apply Special Service Tool: 09213-54015 (90119-08216), 09330-00021 and then disconnect the pulley bolt with Special Service Tool: 09950-50011 (09951-05010, 09952-05010, 09953-05020, 09954-05030), remove the pulley from the crankshaft. A service bolt can be used while Special Service Tool: 09950-50011 (09951-05010, 09952-05010, 09953-05020, 09954-05030) to remove the pulley when needed. Start by removing the starter wire bracket and No.1 timing belt cover through the procedure of disassembling two bolts holding the starter wire bracket while you also take off four bolts securing the timing belt cover. Therefore the first step is to place the crankshaft pulley bolt temporarily to set the No.1 cylinder at TDC/compression before aligning timing marks by turning the crankshaft. Finally inspect the alignment between camshaft timing pulleys and No.3 timing belt cover. Timed marks located on the front and three other areas should be checked; new marks should be added before removing the timing belt when any marks are missing. Begin by unlatching the timing belt tensioner through bolts alternately then take out the two bolts together with tensioner and dust boot before removing the timing belt. A technician should use Special Service Tool: 09960-10010 (09962-01000, 09963-01000) to loosen the camshaft timing pulley bolt before removing the bolt together with the knock pin and timing pulley. You should perform this procedure once more for the LH timing pulley of the camshaft. The No.2 idler pulley removal starts with bolting removal while the No.1 idler pulley demands a 10 mm hexagon wrench during the pivot bolt, idler pulley, and plate washer extraction process. Dismantle the crankshaft timing pulley through the application of Special Service Tool: 09950-50011 (09951-05010, 09952-05010, 09953-05020, 09954-05010 with optional service bolt usage. Check the timing belt for defects that include bending, twisting and touching oil or water or steam but confirm proper installation without damage. Examine the idler pulleys for fluid leaks together with their regular operation while verifying the timing belt tensioner has either no fluid leakages or works properly. First install the crankshaft timing pulley with its key positioned correctly at the key groove then cover it with the pulley after which install the No.1 idler pulley through a 10 mm hexagon wrench until it reaches 35 Nm torque (350 kgf-cm, 26 ft. lbs. torque). Use Special Service Tool: 09960-10010 (09962-01000, 09963-01000) to torque the pulley bolt of the LH camshaft timing pulley at 110 Nm (1,100 kgf-cm, 81 ft. lbs.). The flange side of this pulley needs to face outward with knock pin alignment. After repeating this procedure apply it to the RH camshaft timing pulley. To start the procedure align the No.1 cylinder at TDC compression while you temporarily fasten the crankshaft pulley bolt by its marks. The timing belt installation requires a cool engine and clean pulleys in addition to placing installation marks directly on timing marks. The timing belt tensioner setup requires users to push in the push rod while aligning holes then placing the dust boot. To complete installation of the timing belt tensioner use two bolts which must be torqued to 27 Nm (280 kgf-cm, 20 ft. lbs.). Next check valve timing through crankshaft rotation and timing mark alignment. Industrial placement of the timing belt guide requires installation of the No.1 timing belt cover alongside the starter wire bracket while checking gasket quality. Use Special Service Tool: 09213-54015 (90119-08216) and 09330-00021 to bolt the crankshaft pulley with its set key properly aligned at 295 Nm (3,000 kgf-cm but torque to 217 ft. lbs. Fasten the fan bracket and A/C compressor bracket and surmountarily secure the fan along with its fluid coupling and fan pulleys. The installation process continues with fitting the No.2 fan shroud followed by generator drive belt adjustment and fan tightening with fluid coupling and fan pulley to 5.4 Nm (54 kgf-cm, 48 inch lbs.). Next, connect the A/C compressor to the engine with four bolts at 25 Nm (250 kgf-cm, 18 ft. lbs.) alongside connecting the PS pump to the engine, while all bolts must be securely torqued to specifications. The last steps begin with connecting the upper radiator hose while adding coolant to the engine and then starting the engine to detect leaks before installing the engine under cover followed by a road test for checking abnormal engine noise and operation. Once these checks are complete a final inspection of engine coolant level is performed.

Loosen the fan with fluid coupling and fan pulleys, remove the drive belt for the generator, and take out the No.2 fan shroud and fan with fluid coupling and fan pulleys.

Alternately loosen the two bolts and remove them along with the belt tensioner and dust boot, then remove the timing belt.

Remove the timing belt guide, set the No.1 cylinder at TDC/compression, check the alignment of the camshaft timing pulleys, check for installation marks on the timing belt, and then remove the timing belt tensioner and the timing belt.

Alternately loosen the two bolts and remove them along with the belt tensioner and dust boot.

Disconnect four high-tension cord clamps and remove six bolts, then disconnect the camshaft position sensor connector.

Take out two bolts for the starter wire bracket and four bolts for the timing belt cover.

Use Special Service Tool: 09950-50012 (09951-05010, 09952-05010, 09953-05010) and ensure not to turn the crankshaft pulley.

Remove the A/C compressor connector, the drive belt, and the four bolts.

Alternately loosen the two bolts to remove the timing belt tensioner, then remove the timing belt.

Inspect the timing belt for defects, check idler pulleys for oil leakage and smooth operation, and check the timing belt tensioner for oil leakage and proper push rod movement.