New OE Toyota accessory belt not fitting-- what am I missing?

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Obioban

Obioban

Joined
Apr 20, 2025
Threads
24
Messages
112
Location
West Chester, PA
It's highly under tension just getting it on the tool, as pictured below. Does't come close to fitting around the tensioner, when the tensioner is compressed.

2006 engine. New idlers, tensioners, belt, alternator...

IMG_0300.webp
 
Hmm no idea if they are different between years, but the part number for my '02 2uz was 9091602586. Just installed a couple weeks ago and def the right belt for my engine. Maybe yours too.
 
LazarusTaxa said:
Hmm no idea if they are different between years, but the part number for my '02 2uz was 9091602586. Just installed a couple weeks ago and def the right belt for my engine. Maybe yours too.
Click to expand...
His 90916-02585 matches the 07 LX (one in his sig) from what I can see.
My 2000 has yours. (Seems to be 98/05 LC/LX 2UZs)


OP, are all the new things for a 06+? Belt part number is correct. Next thought is one of those pulleys is for the older motors.
 
compare the original tensioner pulley to the new one. There are 102 mm and 90 mm pulleys for the tensioner.

Edit: Double check your belt routing. It may go from crank to tensioner then to alternator.
 
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leveeguy said:
compare the original tensioner pulley to the new one. There are 102 mm and 90 mm pulleys for the tensioner.

Edit: Double check your belt routing. It may go from crank to tensioner then to alternator.
Click to expand...
Hmm. No longer have the original at this point, but that sounds like a good lead to investigate!

Routing is per the diagram on the hood, so don't think it's likely to be wrong...

Seems like the tensioner is measuring 90mm... which doesn't bode well for that theory.

So, I ordered 166200W101 for the tensioner.

However, I think this may have been an error. I went via the partsouq disagrams, which it looks like it would have given me 166200W100. However, when you click on 166200W100, it says "not available" and gives you 166200W101 as a substitute.

166200W100 looks to still be available from ToyotaPartsNow. Is that my likely issue? Is there any difference in the actual tensioner? or just the pulley (would be much easier and a bit cheaper to just replace the pulley at this point)?
 
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Did you double check the belt routing? I think you need to go over tensioner from alternator to crank pulley.

Should be belt routing sticker under hood
 
IMG_0339.webp

Like this
 
It is best to put belt on after fan attached to fan bracket. I've seen guys do before hand like you show, have issue mounting fan. Such that they think, fan mounted properly. Wherein fan, wasn't actually flush mounted. Fan bracket sheared off, engine overheat and kill the engine.

Additionally:
Your crank sensor/oil sending unit wire housing is routed wrong. It may rub on belt and cut wires.
IMG_0300.webp


IMG_5961.webp

This one also routed wrong. Blue arrow point to where it should be. Behind fan bracket.
Crank wire routed wrong.webp

Needs to be tucked behind fan bracket. Before fan bracket installed.
IMG_3975.webp
055.webp

Correct routing
029.webp
 
Either rout wire harness properly. Or secure/tie to fan bracket. So that it can't rub on belt or pulleys.
 
Will do. Thanks!

I should probably get a new driver side plastic timing belt cover-- my truck doesn't have any of the clips/mounts/etc.
 
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