Parts for removal and installation.
1 - crankshaft pulley mounting bolt (M3=196 Nm), 2 - crankshaft pulley, 3 - timing belt cover No.1, 4 - timing belt cover and generator bracket, 5 - timing belt cover No.2, 6 - fuel injection pump drive toothed pulley, 7 - tension roller, 8-tooth camshaft drive pulley, 9 - tension spring, 10 - timing belt, 11 - crankshaft toothed pulley, 12 - timing belt guide, 13 - intermediate pulley, 14 - oil pump drive toothed pulley.
Removal the timing belt
1. (Models with hydraulic booster) Remove the power steering pump and power steering pump drive belt.
- a) While holding the power steering pump drive belt with your hand, loosen the pulley mounting nut as shown in the figure.
- 6) Loosen the belt tension adjusting bolt and remove the power steering pump drive belt.
- c) Remove the key and pulley of the power steering pump.
- d) Unscrew the three pump mounting bolts and remove it.
2. Remove the generator drive belt.
- a) Loosen the generator mounting bolt, adjusting bolt (or nut) and lock bolt.
- b) Move the generator towards the engine and remove the drive belt.
3. Remove three clamps, unscrew five bolts and remove timing belt cover No.2 together with the gasket.
4. Remove the four glow plugs (see section "Removing the cylinder head").
Note: It is necessary to remove the glow plugs, as this will allow the crankshaft to turn smoothly, which will allow the belt tension to be adjusted correctly.
5. Set the piston of cylinder No.1 to TDC of the compression stroke.
Align the mark on the camshaft pulley with the parting line of the cylinder head and the cylinder head cover by turning the crankshaft pulley clockwise.
6. Remove the crankshaft pulley.
- a) Install the special tool on the crankshaft pulley.
- 6) Using a special device to hold the pulley from turning, unscrew the crankshaft pulley mounting bolt.
- c) Using a special puller, remove the crankshaft pulley.
7. Unscrew the five bolts and remove timing belt cover No.1 together with the gasket and belt guide.
8. Remove the timing belt cover and alternator bracket.
9. Remove the timing belt.
Note: When reusing the timing belt, apply an arrow in the direction of rotation, marks on the timing belt and camshaft sprocket, and align them with the mark on the No.1 timing belt cover as shown in the figure.
- a) Using a screwdriver, remove the timing belt tension roller spring.
Warning: Do not use pliers etc. when removing the spring.
- b) Loosen the tension roller mounting bolt.
- c) Remove the timing belt.
10. Remove the camshaft pulley.
- a) Using a special device to hold the pulley from turning, unscrew the camshaft pulley mounting bolt.
Note: Do not allow the camshaft to turn to avoid the valves hitting the piston crowns.
- b) Using a special tool, remove the camshaft pulley.
(The material is republished from an online website: ToyotaMAN)
11. Remove the tension roller.
12. Remove the fuel injection pump drive toothed pulley.
- a) Using a special device, hold the fuel injection pump drive pulley from turning and unscrew the pulley mounting nut.
Note: Do not use an inertia puller when loosening the nut.
- b) Using a special tool, remove the fuel injection pump drive pulley.
Note: The pulley is spring loaded, so hold it while removing.
13. Remove the intermediate pulley.
14. Remove the oil pump drive pulley.
- a) Using a special device to hold the oil pump pulley from turning, unscrew the pulley mounting nut.
- b) Remove the oil pump pulley.
15. Using a special tool, remove the crankshaft toothed pulley.
During this operation the crankshaft may turn and since it is not synchronized with the camshaft, under certain circumstances the valves may be bent.
