2. On 2004 and later Highlander and all Lexus models, remove the upper hood panel/air intake box deflector (see chapter 11).
3. On 2004 and later Highlander and all Lexus models, remove the windshield wiper arms and windshield wiper motor (see chapter 12).
4. On 2004 and later Highlander and all Lexus models, remove the lower hood panel (see chapter 11).
5. Loosen the right front wheel nuts, but do not remove them completely yet.
6. Raise the front of the vehicle and place reliable supports underneath it. Apply the parking brake and place wheel chocks under the rear wheels. Remove the right front wheel.
Caution: If the vehicle is equipped with electronically controlled air suspension, turn off the ride height control switch.
7. Remove the right front inner fender apron (see chapter 11).
8. Remove the lower engine protection sections (fig. 6.3 a, b).
9. Move the piston of cylinder No.1 to the TDC position (see paragraph 3).
10. Remove the drive belts (see chapter 1).
11. Support the engine with a jack from underneath and remove the engine mount torque rod and its bracket on the engine (fig. 16.1, e). Place a wooden block on the jack head and do not place the jack directly under the oil pan drain plug.
12. Remove the power steering pump and place it aside without disconnecting the hydraulic lines from it. Remove the power steering pump bracket.
13. Remove the upper (No. 2) timing belt cover and the corresponding gasket (Fig. 7.13)
Note: Release the wiring harness above the cover and push it back enough to remove the belt cover.
14. Remove the engine support brackets (fig. 7.14 a, b).
Fig. 7.14, a. Unscrew the bolts and remove the engine mount spacer and the side bracket with the engine mount support
Fig. 7.14, b. First, unscrew the generator bracket bolts (A) and remove the bracket, then unscrew the engine support bracket bolts (B) and separate the bracket from the cylinder block
15. Remove the generator bracket (fig. 7.14, b).
16. Check if there are timing marks on the timing belt. If you intend to reuse the belt and the markings are worn off, apply a new one (Fig. 7.16).
Fig. 7.16. If you intend to continue using the belt and the rectangular alignment marks are not visible or missing, attach new ones
17. Remove the crankshaft pulley bolt. To hold the engine from turning, insert a large screwdriver into the faceplate gear or rest it against the torque converter bolt. A chain wrench can be used to hold the pulley. Use an extension and socket to loosen the pulley bolt.
18. After loosening the crankshaft pulley bolt, the TDC position of the crankshaft may be disturbed. Check it and adjust it again if necessary.
Note: The timing belt pulley located on the crankshaft has a timing mark that aligns with the mark on the oil pump housing. These marks allow easy checking of the TDC alignment even after the crankshaft pulley and lower timing belt cover have been removed.
19. After unscrewing the bolt, remove the pulley from the crankshaft. The pulley should be removed from the shaft by hand (Fig. 7.19), but if it does not come off, use a threaded puller to remove it.
Caution: Do not use a jaw puller. It will cause damage to the damper pulley assembly. Be sure to use the proper adapter to prevent damage to the crankshaft end.
Fig. 7.19. After releasing the crankshaft pulley with the puller, it should be easy to remove by hand
20. Remove the lower (No. 1) timing belt cover and the corresponding gasket.
21. Properly align the marks on the camshafts with the marks on the rear timing belt cover (Fig. 7.21).
Fig. 7.21. Timing belt alignment marks on the crankshaft toothed pulley and camshaft toothed pulleys
1 — Right camshaft toothed pulley
2 - Intermediate pulley
3 — Left camshaft toothed pulley
4 - Tension pulley
5 — Crankshaft toothed pulley
6 — Coolant pump pulley
22. Turn the crankshaft counterclockwise to a position approximately 60° before TDC.
Caution: Do not move the engine pistons past the TDC position for cylinder #1, where accidental contact with the valves is excluded, when the timing belt tension has been released and the timing belt has been removed.
Note: To be able to turn the engine counterclockwise, the crankshaft pulley bolt must be screwed in and tightened sufficiently.
23. Remove the timing belt tensioner (Fig. 7.23).
Caution: Loosen the bolts one at a time, a little at a time, until all tension is released from the timing belt.
Fig. 7.23. Unscrew the two bolts and remove the timing belt tensioner
24. Remove the timing belt in the correct sequence (Fig. 7.21):
- a) Step 1: Remove the belt from the tensioner pulley;
- b) Step 2: Lift the belt over the right camshaft timing pulley;
- c) Step 3: Remove the belt from the idler pulley;
- d) Step 4: Lift the belt over the left camshaft timing pulley;
- d) Step 5: Remove the belt from the coolant pump pulley;
- e) Step 6: Remove the belt from the crankshaft timing pulley.
25. At this point, you can remove the toothed pulleys from the camshafts. Remove the cylinder head cover (see paragraph 5) and when releasing the toothed pulley bolt, hold the camshaft with a wrench by the hexagonal section (Fig. 7.25). Unscrew the bolt and disconnect the toothed pulley.
Fig. 7.25. If the timing pulley toothed pulleys need to be removed, hold the shaft with a wrench by the hex section while unscrewing the pulley mounting bolt
26. Now you can remove the toothed pulley from the crankshaft, but only after removing the holder of this pulley (fig. 7.39). If it will not come off by hand, you may need to use a puller to remove it. Be careful not to damage the part of the pulley that serves as the crankshaft position sensor pulse wheel when removing it.