Timing Belt Replacement (4A-FE Engine) - Removal

· Disconnect the negative battery terminal.

· Drain the washer fluid from the windshield washer reservoir in the engine compartment on the right side. Then remove the mounting screws, disconnect the hose and wiring, and remove the reservoir.

· Remove the camshaft timing cover.

· Loosen the bolts securing the drive pulley to the water pump by one to two turns (this is easier to do while the belt is still installed). NOTE: The pulley will have to be moved aside later to remove the center timing belt cover.

· Chock the rear wheels, raise the front of the vehicle with a jack and support it on stands.

· Remove the front right wheel, then remove the bolts and the splash shield from the underside of the right side of the engine compartment.

· Remove the water pump pulley bolts.

· Remove the generator pivot bolt and lock bolt.

· Remove the generator adjusting bolt and remove the generator belt.

· Remove the water pump pulley bolts.

· Disconnect the high-tension leads and remove the spark plugs.

· Remove the wire harness and clamps around the cylinder head cover, remove the wire harness protective cover 2, and disconnect the crankcase ventilation hoses 6, 7 from the cylinder head cover.

Fig. 2.3.1.1. Engine overview, 4A-FE engine,

where: 1 - high-tension leads; 2 - wire harness protective cover around cylinder head cover; 3 - fuel pressure regulator; 4 - fuel injector delivery pipe; 5 - intake manifold; 6, 7 - crankcase ventilation hoses; 8 - fuel injector connector; 9 - distributor low-tension connector; 10 - distributor; 11 - upper radiator hose of cooling system.

· Remove the nuts, sealing washers, cylinder head cover and cylinder head cover gasket.

· Position No. 1 piston at TDC on the compression stroke by aligning the groove on the crankshaft pulley with the "O" mark on the lower timing belt cover. Check that the hole in the camshaft timing pulley is aligned with the mark on the bearing cap. If not, turn the crankshaft one full revolution (360°).

· Remove the crankshaft pulley bolt and remove the pulley using SST 09213-60017.

· Remove the three timing belt covers.

· Remove the timing belt guide roller.

· Remove the timing belt.

· Remove the outer pulley bolt, push the tensioner pulley as far to the left as possible and temporarily secure it.

· Remove the timing belt.

· Remove the tensioner pulley bolt, tensioner pulley and tensioner spring.

· Slide the pulley off the crankshaft. If necessary, use two screwdrivers, placing shop rags between the engine block and the screwdrivers to prevent damage.

· Remove the camshaft timing pulley. When loosening the bolts, hold the camshaft with a wrench on the hexagonal section.