OEM 2005 Toyota Highlander Timing Chain

2005 Toyota Highlander Parts Questions & Experts Answers

• Q: How to replace the timing chain on 2005 Toyota Highlander?

  A: The first step in timing chain replacement consists of removing the hood sub-assembly, front wheel RH, engine under cover No.1, front fender splash shield front RH, together with the front fender apron seal RH. Position a new gasket along with the drain plug before securing all parts by tightening them to 25 Nm (255 kgf-cm, 18 ft. lbs.). Begin the timing chain replacement by first taking out the exhaust pipe assembly front and then moving to the engine moving control rod with bracket and subsequently extracting the engine mounting stay No.2 RH and engine mounting bracket No.2 RH. The technician should start by removing the fan and generator V belt together with engine cover sub-assembly No.1 and disconnecting the engine wire before taking out the generator assembly and vane pump assembly without cutting the hose. The technician must remove the ignition coil assembly together with ventilation hoses No.1 and No.2 and cylinder head cover sub-assembly while setting the No.1 cylinder to TDC/compression position. Use Special Service Tools 09213-54015 (91651-60855) and 09330-00021 to fix then loosen the crankshaft pulley bolt before removing the bolt and pulley with Special Service Tool: 09950-50013 (containing 09951-05010, 09952-05010, 09953-05020, 09954-05021). The service technicians need to untie the crankshaft position sensor, the oil pan sub-assembly, chain tensioner assembly No.1, and V-ribbed belt tensioner assembly. The installation of engine hangers No.1 and No.2 requires bolts which need torque adjustment to 38 Nm (387 kgf-cm, 30 ft. lbs.) followed by the removal of the engine mounting insulator through engine chain hoist attachment to engine hangers. Before removing the engine essential step involves unfastening the engine mounting insulator FR and steering gear return hose clamp followed by detaching the 4 nuts from the engine mounting insulator RH and subsequently lifting the engine out. Remove the engine mounting bracket RH alongside the timing chain or belt cover sub-assembly while being cautious of contact surfaces damage. Remove first crankshaft position sensor plate, chain tensioner slipper and chain vibration damper Number 1 together with chain sub-assembly and sprocket of crankshaft timing gear. To detach the No.2 chain sub-assembly from the engine start by turning the crankshaft 90 degrees counterclockwise while putting a 4.0 mm bar through the oil pump driven sprocket adjusting hole and removing the bolt, chain tensioner plate, spring and nut. Set the crankshaft key to the left horizontal position then initialize the mark links with timing marks before temporarily tightening the oil pump driven sprocket with the nut to install the No.2 chain sub-assembly. Position the adjusting hole through the groove while mount the nut with a 4 mm bar and torque to 30 Nm (306 kgf-cm, 22 ft. lbs.). Perform a 90 degrees counter-clockwise rotation of the crankshaft before aligning its key with the top portion. Install chain vibration damper No.1 with a torque of 9.0 Nm (92 kgf-cm, 80 inch lbs.) while setting No.1 cylinder to TDC/compression position using Special Service Tool: 09309-37010 to tap in the sprocket. The service procedure involves installing the chain tensioner slipper followed by torquing it to 19 Nm (194 kgf-cm, 14 ft. lbs.). Subsequently install the crankshaft position sensor plate No.1. Install the timing chain or belt cover sub-assembly with correct bolt torques of 9.0 Nm (92 kgf-cm, 80 inch lbs.) for bolt A, 21 Nm (214 kgf-cm, 15 ft. lbs.) for bolt B and 43 Nm (438 kgf-cm, 32 ft. lbs.) for bolt C while using seal packing (Part No. 08826-00080 or equivalent) before applying torques of 9.0 Nm (92 kgf-cm, 80 inch lbs.) for the nut. First install the stud bolt to the drive belt tensioner then torque it to 10 Nm (102 kgf-cm, 7 ft. lbs.). Subsequently install chain tensioner assembly No.1 with plunger completely pushed in before securing it. The set of components includes the cylinder head cover sub-assembly and additional items such as the ignition coil assembly (torque to 19 Nm (194 kgf-cm, 14 ft. lbs.)), vane pump assembly, generator assembly, engine wire, fan and generator V belt, engine mounting bracket No.2 RH (torque to 52 Nm (531 kgf-cm, 38 ft. lbs.) and engine mounting stay No.2 RH (torque to 64 Nm (653 kgf-cm, 47 ft. lbs.)). Install the engine moving control rod with bracket followed by the exhaust pipe assembly front, front wheel RH and the hood sub-assembly (torque to 13 Nm (133 kgf-cm, 10 ft. lbs.)). Finish the process by pouring engine oil while inspecting for any fluid leaking from the components.