Toyota 13568-09080
Timing Belt

You should begin timing belt removal by taking off the RH front wheel followed by the fender apron seal before proceeding with generator drive belt and PS pump drive belt bolt removal. The timing belt removal procedure starts with disconnecting the engine coolant reservoir hose from the water outlet then breaking the ground strap connectors while removing the engine moving control rod and No.2 RH engine mounting bracket and No.2 generator bracket by loosening the pivot bolt followed by removing the nut and bracket. Special Service Tools 09213-54015 (91651-60855) and 09330-00021 and 09950-50012 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05020) should be used to remove the crankshaft pulley components. First remove the 4 bolts from the No.1 timing belt cover followed by removing the timing belt guide and then proceed to remove the No.2 timing belt cover after disconnecting engine wire protector clamps and precision removal of the 5 bolts. Start by removing the 2 bolts and nut securing the RH engine mounting bracket. After which install the crankshaft pulley bolt temporarily to align the timing marks while rotating the crankshaft at TDC/compression and verify the camshaft timing pulleys. Every timing belt should get a thorough examination to detect its three installation marks and one front mark. New marks must be placed first whenever existing marks are not visible before removing the timing belt. Begin with timing belt tensioner removal after 2 bolt rotation then disconnect the timing belt before moving on to the camshaft timing pulleys. Special Service Tools 09249-63010 and 09960-10010 (09962-01000, 09963-01000) are needed for Right-hand and Left-hand timing pulley service respectively. The technician should begin by using a ten-millimeter hexagon wrench to remove the No.2 idler pulley and the No.1 idler pulley before moving on to the crankshaft timing pulley removal through the procedure of bolt and timing belt plate removal along with the use of Special Service Tool: 09950-50012 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05010) to lift out the pulley while preserving the sensor part from scratching. Check the timing belt for defects while it must stay straight and untwisted and avoid contact with oil water and steam. Also inspect for any oil leakage from the idler pulleys and timing belt tensioner as well as their smooth operation. Installation should begin with the crankshaft timing pulley by aligning its pulley set key followed by installation of the timing belt plate which requires 8 Nm (80 kgf-cm, 69 inch lbs.) of torque before applying Part No. 08833-00080 adhesive like THREE BOND 1344, LOCTITE 242 or equivalent to the No.1 idler pulley and torquing to 34 Nm (350 kgf-cm, 25 ft. lbs.). After installing the 43 Nm torque (440 kgf-cm, 32 ft. lbs.) No.2 idler pulley attach the RH camshaft timing pulley with the flange side facing outward before torquing the pulley bolt to 88 Nm (900 kgf-cm, 65 ft. lbs.) using Special Service Tool: 09249-63010, 09960-10010 (09962-01000, 09963-01000). Fasten the LH camshaft timing pulley with its flange facing inside and complete the torque to 125 Nm (1,300 kgf-cm, 94 ft. lbs.). Set the No.1 cylinder at TDC/compression while verifying the timing marks' position before installing the timing belt according to sequence when the engine remains cool and pulleys are cleaned. The timing belt tensioner needs setting through the use of a 1.27 mm hexagon wrench to activate the push rod followed by installation and bolt tightening to 27 Nm (280 kgf-cm, 20 ft. lbs.). Flip the crankshaft twice to check timing marks but keep the timing belt if any marks fail to align. Installation of the RH engine mounting bracket requires 28 Nm (290 kgf-cm, 21 ft. lbs.) torquing followed by No.2 timing belt cover installation with a 5-bolt torque to 8.5 Nm (85 kgf-cm, 74 inch lbs.). Install the timing belt guide then the No.1 timing belt cover before adding the crankshaft pulley with proper key alignment while torquing the bolt to 215 Nm (2,200 kgf-cm, 159 ft. lbs.). Reinstall the RH fender apron seal and front wheel following a vehicle road test which checks for abnormal noise, shock, slippage, correct shift points and smooth operation. The final assembly includes the No.2 generator bracket, the No.2 RH engine mounting bracket and engine moving control rod, along with reconnecting ground strap connectors and coolant reservoir hose and drive belts installation.

To replace the timing belt, first remove the front wheel RH, front fender apron seal RH, V (cooler compressor to crankshaft pulley) belt No. 1, vane pump V belt, engine moving control rod, engine mounting stay No. 2 RH, generator bracket No. 2, and crankshaft pulley by using Special Service Tool: 09213-54015 (91651-60855), 09330-00021 to loosen the pulley bolt and Special Service Tool: 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09954-05030) to remove it, ensuring to apply lubricating oil on the threads and tip of the center bolt 100 before use. The technician needs to begin by detaching the engine wire protector clamps and extracting the 5 bolts that secure the timing belt No. 1 cover and timing belt No. 2 cover. This procedure requires setting No. 1 cylinder at TDC/compression to allow removal of the timing belt tensioner before installing the crankshaft pulley bolt with the washer while turning the crankshaft clockwise to align timing marks. Test the timing belt for any signs of defect while checking that it stays straight and straight and avoids contact with oil, water, or steam. Also check whether the timing cover gasket and its installation are correct. Reinstall the timing belt when needed and engage in testing idler pulleys and the water pump for their functioning state as well as checking for any leaks. Secure the crankshaft pulley bolt along with its washer temporarily before you correctly position the timing marks. Then use Special Service Tool: 09960-10010 (09962-01000, 09963-01000) for camshaft pulley timing mark alignment. Place the timing belt correctly by orienting the front mark to face forward then synchronize its installation marks with the crankshaft and camshaft pulleys timing marks. Install timing belt guide No. 2 followed by the transverse engine mounting bracket with 28 Nm (286 kgf-cm, 21 ft. lbs.) torque and timing belt No. 2 cover and timing belt No. 1 cover while checking for gasket cracks then torquing to 8.5 Nm (87 kgf-cm, 76 inch lbs.). Install crankshaft pulley by aligning the pulley set key and using Special Service Tool: 09213-54015 (91651-60855), 09330-00021 to install the pulley bolt with a torque of 215 Nm (2,192 kgf-cm, 159 ft. lbs.), followed by generator bracket No. 2 with a torque of 28 Nm (286 kgf-cm, 21 ft. lbs.), engine mounting stay No. 2 RH, engine moving control rod, vane pump V belt, V (cooler compressor to crankshaft pulley) belt No. 1, inspect drive belt deflection and tension, and finally reinstall the front wheel RH with a torque of 103 Nm (1,050 kgf-cm, 76 ft. lbs.).

To replace the timing belt, begin by removing the front wheel RH, front fender apron seal RH, V (cooler compressor to crankshaft pulley) belt No.1, vane pump V belt, engine moving control rod, engine mounting stay No.2 RH, generator bracket No.2, and crankshaft pulley using Special Service Tool: 09213-54015 (91651-60855), 09330-00021 to loosen the pulley bolt and Special Service Tool: 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09954-05030) to remove it, ensuring to apply lubricating oil on the threads and tip of the center bolt 100 before use. The procedure begins with removing the engine wire protector clamps to take off 5 bolts then remove timing belt guide No.2 and engine mounting bracket RH, timing belt No.1 cover, timing belt No.2 cover and the timing belt itself. Next, set the No. 1 cylinder to TDC/compression to temporarily install the crankshaft pulley bolt with the washer while turning the crankshaft clockwise to align timing marks before checking the camshaft timing pulleys alignment. To reuse the timing belt maintain its original installation marks until measurement or mark them you will use for reference before removing it. Set the No. 1 cylinder to approximately 60° BTDC/compression position. Set the No. 1 cylinder to TDC/compression at approximately 60° BTDC before removing the belt tensioner without activating its plunger due to the necessity for proper crankshaft pulley orientation. The installation of the new timing belt requires preventing any activity that would involve bending or twisting or contact with oil water or steam and maintaining clean pulleys. Install the crankshaft pulley bolt together with its washer followed by turning the crankshaft counterclockwise to about 60° while using Special Service Tool: 09960-10010 (09962-01000, 09963-01000) to correctly position the timing marks. The timing belt installation requires alignment of the front mark toward the front with the installation marks matching the pulley timing marks. Press in the push rod of the timing belt tensioner assembly using less than 9.8 kN (1,000 kgf, 2,205 lbs) force and line up the holes before securing it with two bolts at 27 Nm (280 kgf-cm, 20 ft. lbs.). Then check the timing marks after two crankshaft clockwise turns. The work proceeds with timing belt guide No.2 facing engine front and engine mounting bracket RH receiving torque of 28 Nm (286 kgf-cm, 21 ft. lbs.). Afterward, install timing belt No.2 cover with timing belt No.1 cover at 8.5 Nm (87 kgf-cm, 76 inch lbs.) yet be mindful to maintain gasket integrity. Prefinal installation adds the engine wire protector cover. Place the set key correctly then use Special Service Tools 09213-54015 (91651-60855), 09330-00021 at 220 Nm (2250 kgf-cm, 162 ft. lbs.) to install the pulley bolt while proceeding with installation of generator bracket No.2 at 28 Nm (286 kgf-cm, 21 ft. lbs.), engine mounting stay No.2 RH, engine moving control rod, vane pump V belt, V (cooler compressor to crankshaft pulley) belt No.1, inspect drive belt tension, and reinstall the front wheel RH.

To replace the timing belt, begin by removing the front wheel RH, front wiper arm head cap, front wiper arms RH and LH, cowl top ventilator louver sub-assembly, wiper link assembly, cowl top to cowl brace inner No.1, cowl top panel sub-assembly outer front, front fender apron seal RH, V (cooler compressor to crankshaft pulley) belt No.1, vane pump V belt, engine moving control rod (removing 5 bolts), engine mounting stay No.2 RH (removing the bolt and wire harness bracket, then the bolt, engine mounting stay No.2, and engine mounting bracket No.2), generator bracket No.2 (removing the nut), and crankshaft pulley using Special Service Tool: 09213-54015 (91651-60855), 09330-00021 to loosen the pulley bolt and then remove it with Special Service Tool: 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05031) after applying lubricating oil on the threads and tip of the center bolt 150. Next, remove timing belt No.1 cover, timing belt No.2 cover (disconnecting engine wire protector clamps), engine mounting bracket RH (removing 2 bolts, nut), timing belt guide No.2, and the timing belt itself by setting No. 1 cylinder to TDC/compression, temporarily installing the crankshaft pulley bolt and washer, turning the crankshaft clockwise to align timing marks, checking alignment of camshaft timing pulleys and No. 3 timing belt cover, and ensuring the crankshaft pulley is at the correct angle to avoid contact between the piston head and valve head. Perform a thorough inspection of the timing belt which should not bend nor twist nor come into contact with oil or water or steam and evaluate the gasket condition on the timing cover as well as the proper installation. Timing belts that receive reinstallation need to show proper installation marks. First clean all pulleys before examining the idler pulleys and water pump for lubrication and leaks and finally install the new timing belt by aligning its installation marks to the timing marks. The installation of Chain Tensioner assembly No.1 requires inserting the push rod while lining up all holes followed by temporary attachment with two bolts at 27 Nm. The correct procedure requires timing belt guide No.2 followed by engine mounting bracket RH installation at a torque of 28 Nm and timing belt No.2 cover with 8.5 Nm torque followed by timing belt No.1 cover installation at 8.5 Nm torque and ending with engine wire protector cover installation. Use Special Service Tool: 09213-54015 (91651-60855) while aligning the keyway for the crankshaft pulley before installation along with generator bracket No.2 at 28 Nm torque setting and additional components including engine mounting stay No.2 RH at 64 Nm torque, wire harness bracket at 8.4 Nm torque and engine moving control rod with specified sequence torque values. Install the vane pump V belt before inspecting drive belt deflection and tension and putting together the outer front of cowl top panel sub-assembly along with cowl top to cowl brace inner No.1, wiper link assembly, front wiper arms LH and RH, and front wheel RH.

Ensure the flange side of the RH camshaft timing pulley faces outward and the flange side of the LH camshaft timing pulley faces inward.

Remove the engine moving control rod by taking out the 3 bolts.

Install the RH camshaft timing pulley with the flange side facing outward and the LH camshaft timing pulley with the flange side facing inward, using the appropriate Special Service Tools.

Start with the crankshaft timing pulley, aligning the pulley set key and installing the timing belt plate with a torque of 8 Nm (80 kgf-cm, 69 inch lbs.).

Check for 3 installation marks and a front mark; if they are missing, place new marks before removing the timing belt.

Remove the timing belt from the camshaft timing pulley by loosening the No.1 idler pulley mounting bolt and shifting it left, then remove the camshaft timing pulley using Special Service Tool: 09249-63010, 09960-10010.

Remove the No.2 idler pulley and No.1 idler pulley using a 10 mm hexagon wrench.

Check for three installation marks and a front mark; if missing, place new marks before removal.

Special Service Tool: 09249-63010 and 09960-10010.

Ensure pulleys are clean and free of oil or water, inspect idler pulleys and water pump for smooth operation and leaks.

Check timing marks after turning the crankshaft 2 revolutions.

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

Install the No.1 idler pulley with adhesive and torque to 34 Nm, followed by the No.2 idler pulley torqued to 43 Nm.

Use SST 09249-63010, 09960-10010 (09962-01000, 09963-01000) for the right-hand timing pulley and SST 09960-10010 (09962-01000, 09963-01000) for the left-hand timing pulley.