Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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Special Precautions Special Precautions Disconnect battery earth lead. DO NOT turn crankshaft or camshaft when timing belt removed. Remove glow plugs to ease turning engine. Turn engine in normal direction of rotation (unless otherwise stated). DO NOT turn engine via camshaft or other sprockets. Observe all tightening torques. Check diesel injection pump timing after belt replacement. Removal Removal 1. Support engine. 2. Remove: Air filter and air intake hoses. Auxiliary drive belts. RH engine mounting. Vacuum pipe bracket. Timing belt upper cover [1]. 3. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure crankshaft sprocket timing marks aligned [2]. 4. Insert M6 x 1,00 bolt in camshaft sprocket and M8 x 1,25 bolt in injection pump sprocket to lock sprockets in position [3]. NOTE: If locating holes not aligned: Turn crankshaft one turn. 5. Remove: Crankshaft pulley (4 bolts). Timing belt lower cover [4]. 6. Slacken tensioner bolts [6]. Remove tensioner spring [5]. 7. Move tensioner pulley away from belt. Lightly tighten bolts. 8. Remove timing belt. Installation Installation 1. 2. 3. 4. 5. Use crankshaft pulley to check TDC marks aligned [2]. Ensure locking bolts located correctly [3]. Fit timing belt in clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets. Temporarily fit crankshaft pulley. Ensure timing marks aligned [2]. Fit tensioner spring [5]. Corsa-B/Corsavan/Combo: Slacken tensioner bolts [6]. Allow tensioner to operate. Remove locking bolts [3]. Tighten tensioner bolts to 19 Nm [6]. Turn crankshaft slowly two turns clockwise. Ensure timing marks aligned [2]. 6. Astra-F/Vectra/Cavalier: Slacken tensioner bolts [6]. Temporarily fit crankshaft pulley. Remove locking bolts [3]. Turn crankshaft 60° anti-clockwise (against normal direction of rotation) [7]. Tighten tensioner bolts to 19 Nm [6]. Turn crankshaft slowly two turns + 60° clockwise until timing marks aligned [2]. 7. 8. 9. 10. 11. Ensure timing marks aligned [2]. Ensure locking bolts can be inserted in sprockets [3]. If not: Repeat tensioning procedure. Remove crankshaft pulley. Fit timing belt lower cover [4]. Fit crankshaft pulley. Tighten bolts to 20 Nm. Install components in reverse order of removal.

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Removal 1. Disconnect negative battery cable. Disconnect intake air temperature sensor connector from intake air duct. Disconnect the air intake tube from the throttle body. Disconnect the breather tube from the valve cover. Remove the air filter housing. 2. Raise and support the vehicle. Remove right front wheel. Remove right front splash shield from wheelwell. Remove serpentine accessory drive belt. 3. Remove crankshaft pulley bolts. It is NOT necessary to remove crankshaft sprocket center bolt. Remove crankshaft pulley. Lower vehicle. 4. Support engine assembly from above with Support Fixture (J-28467-B). See Fig. 1 . Remove engine mount bracket from timing belt end of engine. See Fig. 2 . 5. Remove front timing belt cover. Using crankshaft center bolt, rotate crankshaft one full turn clockwise (as viewed from timing belt end of engine). 6. Align mark on crankshaft sprocket with notch at bottom of rear timing belt cover. See Fig. 3 . Align camshaft sprocket timing marks with notches on valve cover. See Fig. 4 . CAUTION: Engine damage could result if camshaft sprockets are not properly aligned with notches on valve cover. 7. Loosen the automatic tensioner bolt. Use an Allen wrench to rotate tensioner and relieve tension on timing belt. See Fig. 5 . Remove timing belt. Installation 1. Ensure crankshaft and camshaft timing timing marks are still aligned. Install the timing belt. See Fig. 6 . Turn the timing belt tensioner clockwise to tension the timing belt. Turn tensioner until the pointer aligns with the notch on the rear timing belt cover. Tighten automatic tensioner bolt. See TORQUE SPECIFICATIONS . 2. Using crankshaft center bolt, turn crankshaft clockwise (as viewed from timing belt end of engine) 2 full revolutions. Ensure timing belt tensioner pointer is still aligned with notch. 3. If timing belt tensioner is correctly aligned, install timing belt cover. Install the engine mount bracket on the timing belt end of engine. Install crankshaft pulley. Install serpentine accessory drive belt. Install right front splash shield. Install right front wheel. 4. Install air filter housing. Connect air intake temperature sensor connector. Connect negative battery cable.

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1. Remove spark plugs (12405). 2. Align crankshaft (6303) so number one piston is at TDC (top dead center) as indicated by timing marks. Refer to illustration. 3. Remove outer timing belt cover as outlined in this section. 4. CAUTION: If you attempt to remove timing belt or adjust tension without loosening both timing belt tensioner adjusting bolt and spring pivot bolt, you will break Camshaft Belt Tension Adjusting Tool T74P-6254-A when you attempt to relieve tension on belt. Loosen timing belt spring pivot bolt. Do not remove. 5. Hold tensioner with Camshaft Belt Tension Adjusting Tool T74P-6254-A. 6. While holding tensioner, loosen adjusting bolt and gradually release spring tension. 7. Using adjusting tool, rotate tensioner, against spring pressure, as far clockwise as possible. While holding, tighten adjusting bolt to hold tensioner away from belt. 8. Remove timing belt. Camshaft Timing Belt, 2.3L I-4 Installation NOTE: Care must be taken during timing belt installation to prevent damage to the inner timing cover.

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Replacement Interval Guide Toyota recommend: 1993: Replacement every 60,000 miles or 5 years, whichever occurs first. 1994 : Replacement every 63,000 miles or 5 years, whichever occurs first. 1996 : Replacement every 60,000 miles or 5 years, whichever occurs first (Colorado only). The previous use and service history of the vehicle must always be taken into account. Check For Engine Damage Check For Engine Damage Removal Removal 1. Remove timing belt cover [1]. 2. Turn crankshaft clockwise until timing marks aligned [2]. 3. Ensure timing marks aligned: 1KZ-T/TE: [3]. 1HD-FT/1HD-FTE: [4]. 4. Evenly slacken and remove automatic tensioner unit bolts [5]. 5. Remove: Automatic tensioner unit [6]. Tensioner pulley bolt [7]. Tensioner pulley [8]. Timing belt. Installation Installation 1. 2. 3. 4. 5. 6. 7. Check tensioner pulley for smooth operation [8]. Replace if necessary. Remove dust cover. Check tensioner body for leakage or damage [6]. Check pushrod protrusion is 9,0-9,8 mm [9]. Check pushrod does not move when pushed against a firm surface. If pushrod moves: Replace automatic tensioner unit. Slowly compress pushrod into tensioner body until holes aligned. Use press. Retain pushrod with 1,5 mm Allen key through hole in tensioner body [10]. Fit dust cover. Ensure timing marks aligned [2]. Ensure timing marks aligned: 1KZ-T/TE: [3]. 1HD-FT/1HD-FTE: [4]. 8. 9. 10. 11. 12. 13. 14. 15. 16. Fit timing belt in anti-clockwise direction, starting at lower sprocket. Ensure belt is taut between sprockets. Fit tensioner pulley [8]. Tighten bolt to 34 Nm [7]. Push tensioner pulley against belt. Install automatic tensioner unit [6]. Tighten bolts evenly to 13 Nm [5]. Remove Allen key from tensioner body to release pushrod. Turn crankshaft two turns clockwise. Ensure timing marks aligned [2] & [3] or [4]. If not: Repeat installation and tensioning procedures. Install components in reverse order of removal. Reset timing belt replacement warning lamp as follows: -Runner/Landcruiser: Remove grommet in speedometer housing. Depress switch using a thin screwdriver [11]. 17. Colorado: Remove speedometer housing. Remove screw indicated and insert in alternative location [12]. 18. Amazon: Lamp illuminates at 90,000 miles. Return vehicle to dealer.

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NOTICE: Always turn the crankshaft clockwise. (c) Check that the timing marks of the camshaft timing pul- leys and No.3 timing belt cover are aligned. If not, turn the crankshaft pulley 1 revolution (360°). (d) Remove the crankshaft pulley bolt. IF REUSING TIMING BELT, CHECK INSTALLATION MARKS ON TIMING BELT Check that there are 3 installation marks and front mark on the timing belt. If the installation and front marks have disappeared, before re- moving the timing belt, place 3 new installation marks on the timing belt to match the timing marks of the timing pulleys, and place a new front mark on the timing belt. 18. 19. REMOVE TIMING BELT TENSIONER Alternately loosen the 2 bolts, and remove them, the belt ten- sioner and dust boot. 20. REMOVE TIMING BELT 21. (a) REMOVE RH CAMSHAFT TIMING PULLEY Using SST, loosen the pulley bolt. SST 09960–10010 (09962–01000, 09963–01000) Remove the bolt, knock pin and timing pulley. (b) 22. (a) REMOVE LH CAMSHAFT TIMING PULLEY Using SST, loosen the pulley bolt. SST 09960–10010 (09962–01000, 09963–01000) Remove the bolt, knock pin and timing pulley. (b) 23. REMOVE NO.2 IDLER PULLEY Remove the bolt and idler pulley. 24. REMOVE NO.1 IDLER PULLEY Using a 10 mm hexagon wrench, remove the pivot bolt, idler pulley and plate washer. 25. REMOVE CRANKSHAFT TIMING PULLEY Remove the timing pulley. HINT: If the pulley cannot be removed by hand, use SST and a service bolt to remove the timing pulley. SST 09950–50011 (09951–05010, 09952–05010, 09953–05020, 09954–05011)