TECHNICAL INSTRUCTIONS FOR SAFETY RECALL B0M CRANKSHAFT PULLEY REPLACEMENT CERTAIN 2004 MODEL YEAR AVALON CERTAIN 2004 2005 MODEL YEAR CAMRY, CAMRY SOLARA, HIGHLANDER, SIENNA CERTAIN 2006 MODEL YEAR HIGHLANDER HV
I. OPERATION FLOW CHART 2
II. IDENTIFICATION OF COVERED VEHICLES A. COVERED VIN RANGE Model WMI Year VIN Range VIN Range Model WMI Year VDS Range VDS Range Avalon 4T1 2004 BF28B U375678 - U391317 CA30P U033162 - U039364 U033135 - U036458 2004 CA38P U033055 - U039362 BA30K U505195 - U505853 Camry FA38P U032975 - U039242 4T1 U033166 - U036460 Solara CA30P U038637 - U061624 BA32K U505009 - U505868 2005 CA38P U038995 - U061645 2004 U080081 - U082147 FA38P U034229 - U061635 BF30K U587786 - U590029 DP21A 0037844-0043214 U079819 - U082153 2004 EP21A 0057931-0067233 BF32K U587756 - U590028 GP21A 0037859-0043210 4T1 Highlander JTE U031865 - U061616 DP21A 0043215-0077242 BA30K U505768 - U508793 2005 EP21A 0067234-0117974 Camry JTD 2005 2004 2005 U036063 - U061656 GP21A 0042673-0077238 BA32K U505800 - U508798 DW21A 0001003-0001084 Highlander U081927 - U100932 JTE 2006 EW21A BF30K HV 0001009-0001524 U586244 - U606955 HW21A 0001275-0001275 U081782 - U100936 BA22C S022711 - S028701 BF32K U589777 - U606951 BA23C S023039 - S028702 2004 BA30K 0023312-0023553 ZA22C S176784 - S221159 BA32K 0023361-0023585 ZA23C S177068 - S221167 Sienna 5TD BF30K 0157925-0158353 BA22C S024277 - S039019 BF32K 0157860-0158338 BA23C S028704 - S039028 2005 BA30K 0023681-0024525 ZA22C S218195 - S287017 BA32K 0023546-0024526 ZA23C S217835 - S287016 BF30K 0158357-0161892 BF32K 0158358-0161894 NOTE: Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Safety Recall, and that the campaign has not already been completed prior to dealer shipment or by another dealer. TMS warranty will not reimburse dealers for repairs conducted on vehicles that are not covered or were completed by another dealer. 3
III. PREPARATION A. PARTS Model Part Number Part Description Quantity All 04001-01120 Crankshaft Pulley* 1 *An inspection is necessary to determine if crankshaft pulley replacement is necessary Ancillary Parts Only a small number of vehicles will require the replacement of these parts. Only replace these parts after performing all inspections steps. Model Part Number Part Description Quantity All 90916-A2009 or Power Steering Drive Belt 1 All Avalon Camry Camry Solara Sienna Highlander Highlander HV 90080-91088-83 90080-91239 or 99366-21040-83 A/C & Alternator Drive Belt 1 11321-0A020 Timing Belt Cover No. 1 1 Avalon 11302-0A020 Timing Belt Cover No. 1 1 All 13568-29025 Timing Belt 1 Avalon Camry Camry Solara Sienna Highlander Highlander HV 13540-20030 Timing Belt Tensioner 1 Avalon 13540-20021 Timing Belt Tensioner 1 B. TOOLS, SUPPLIES & EQUIPMENT Standard hand tools Torque wrench Techstream Belt tension gauge SST These are essential special service tools that the dealership should have. Tool Number Tool Name 09213-54015 Crankshaft Pulley Holding Tool 09330-00021 Companion Flange Holding Tool 09950-50013 Universal Puller Set C 09960-10010 Variable Pin Wrench Set IV. BACKGROUND In certain 2004 and 2005 MY Camry, Camry Solara, Highlander, Sienna, certain 2004 MY Avalon, and certain 2006 MY Highlander HV vehicles equipped with a 1MZ-FE or 3MZ-FE V6 engine, the amount of adhesive agent applied between the outer ring and the torsional rubber damper (inner ring) in the crankshaft pulley may be inadequate. If the adhesive is insufficient, there is a possibility that the outer ring may become misaligned and it may not properly rotate with the inner ring, causing noise and/or illumination of the discharge warning light. In some cases, the belt for the power steering pump may become detached from the pulley. The driver may notice a sudden increase in steering effort. A sudden increase in steering effort could increase the risk of a crash. 4
V. WORK PROCEDURE A. INSPECT THE CRANKSHAFT PULLEY 1) Remove the front wheel RH. 2) Remove the front fender apron seal RH. 3) Inspect the crankshaft pulley. INSPECTION RESULT ACTION REQUIRED Mark present Proceed to STEP B. INSPECT THE TIMING BELT COVER No. 1 Mark NOT present The vehicle IS NOT affected. The campaign is complete. B. INSPECT THE TIMING BELT COVER No. 1 1) Remove the crankshaft pulley. 2) Inspect the surface of the timing belt cover. NOTE: If the crankshaft pulley inner and outer ring have begun to separate, damage may occur to the timing belt cover and timing belt. INSPECTION RESULT ACTION REQUIRED Cover NOT damaged Replace the crankshaft pulley. Replace the crankshaft pulley, timing belt cover No. 1, and both drive belts. Replace the crankshaft pulley, timing belt cover No. 1, both drive belts, timing belt, and timing belt tensioner. NOTE: This condition is rare, only replace timing belt and tensioner if a hole in the cover has been verified. Inappropriate parts replacement will result in the claim being debited. Refer to TIS for instructions on applicable parts replacement. Timing Belt Avalon Timing Belt Sienna Timing Belt Camry Timing Belt Highlander Timing Belt Camry Solara Timing Belt Highlander HV NOTE: Drive belt tension and deflection specifications may be incorrect in the repair manual, refer to the table in the appendix of these instructions for the correct specifications. VERIFY REPAIR QUALITY Confirm the supplier mark is identified before replacing the crankshaft pulley Confirm ALL removal and installation steps are followed according to the repair manual If you have any questions regarding this recall, please contact your regional representative 5
VI. APPENDIX A. INSPECT AND CLEAN THE TIMING BELT PULLEYS If the crankshaft pulley inner and outer ring have begun to separate, damage may occur to the timing belt cover and timing belt. Follow these steps to confirm the timing belt pulleys are free of debris from the possibly damaged components. Confirm there is no metal debris on the crankshaft sensor pickup wheel. 1) Confirm all idler pulleys turn smoothly. 2) Clean all pulleys using a shop cloth soaked in brake cleaner. 3) Use an air gun to confirm all pulleys are clean and free of debris. 6
Confirm there is no metal debris on the crankshaft sensor pickup wheel. INSPECT AND CLEAN THE TIMING BELT PULLEYS CONTINUED 7
B. DRIVE BELT TENSION & DEFLECTION SPECIFICATIONS TENSION SPECIFICATIONS BELT NEW USED A/C & Alternator 139 to 192 lbf 66 to 110 lbf (617 to 853 N) (294 to 490 N) Power Steering 132 to 154 lbf 55 to 88 lbf (588 to 686 N) (245 to 392 N) DEFLECTION SPECIFICATIONS: PRESSING FORCE 22 lbf (98 N) BELT NEW USED A/C & Alternator 0.358 to 0.413 in. 0.433 to 0.531 in. (9.1 to 10.5 mm) (11.0 to 13.5 mm) Power Steering 0.315 to 0.394 in. 0.433 to 0.551 in. (8 to 10 mm) (11 to 14 mm) C. CAMPAIGN DESIGNATION DECODER Examples: A0D = Launched in 2010, Remedy Phase, 4 th Campaign Launched in 2010 B1E = Launched in 2011, Interim Phase, 5 rd Campaign Launched in 2011 C1C = Launched in 2012, Interim Phase, 3 rd Campaign Launched in 2012 D. RECALL PARTS DISPOSAL As required by Federal Regulations, please make sure all recalled parts (original parts) removed from the vehicle are disposed of in a manner in which they will not be reused, unless requested for parts recovery return. 8