Crankshaft pulley removal (4JJ3 with DPD)

1. Component views

Crankshaft pulley

Part name

  1. Bolt
  2. Washer
  3. Crankshaft pulley

Tightening torque

1-1: 30 N・m { 3.1 kgf・m / 22 lb・ft }

1-2: 180 °

1-3: 60 °

2. Preliminary and post procedures

1. Preliminary procedures

1) Open the engine hood.

2) Disconnect the battery cable from the battery negative terminal.

Caution

  • After turning OFF the ignition switch (power mode for models with passive entry and start system), do not disconnect the battery cable within 3 minutes.
  • If the battery cable is disconnected within 3 minutes, the vehicle electronic control system may malfunction.
  • If the battery cable is disconnected, perform the setting of the front door power window switch with AUTO UP/AUTO DOWN function after connecting the battery negative terminal.

3) Raise the vehicle.

3. Underguard removal

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard removal".

4. Starter motor removal

Refer to "1.Engine 1J.Electrical(4JJ3 with DPD) starter motor removal".

5. Coolant drain

Warning

  • Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in burns caused by the release of steam or hot water.
  • When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled and slowly turn to release pressure.

1) Remove the radiator cap from the radiator.

2) Loosen the radiator drain plug, and drain the coolant into a pan.

3) Loosen the drain plug on the cylinder block, and drain the coolant to a pan.

Legend

  1. Drain plug

4) Apply LOCTITE 262 or equivalent to the threaded portion of the cylinder block side drain plug.

5) Tighten the drain plug on the cylinder block.

Tightening torque: 21.6 N・m { 2.2 kgf・m / 16 lb・ft }

6) Tighten the radiator drain plug.

6. Engine cover removal

1) Remove the engine cover from the engine.

Legend

  1. Engine cover

7. Air duct removal

1) Remove the intake air duct from the air cleaner and radiator core support.

Legend

  1. Intake air duct
  2. Clip

2) Remove the PCV hose from the cylinder head cover and air duct.

Legend

  1. PCV hose
  2. Clamp

3) Remove the air duct from the air cleaner and turbocharger.

Legend

  1. Air duct

8. Air cleaner removal

1) Disconnect the connector from the MAF and IAT sensor.

2) Remove the air cleaner from the vehicle.

Legend

  1. Air cleaner
  2. MAF and IAT sensor

9. Intake air duct removal

1) Disconnect the connector from charge air cooler temperature sensor 2.

2) Disconnect the air intake hose from the intercooler.

3) Remove the intake air duct from the intake throttle valve.

10. Radiator reserve tank removal

1) Disconnect the radiator reserve tank hose from the radiator.

2) Remove the radiator reserve tank from the fan guide.

11. Radiator upper hose removal

1) Remove the radiator upper hose from the thermostat and radiator.

Legend

  1. Radiator upper hose

12. Fan guide removal

1) Remove the fan shroud from the fan guide.

2) Remove the fan guide from the radiator.

Legend

  1. Fan shroud
  2. Fan guide
  3. Radiator

13. A/C compressor drive belt removal

1. M/T models (Euro 5 or above)

1) Loosen the tension pulley lock nut.

2) Loosen the tension pulley adjust bolt.

3) Remove the A/C compressor drive belt from the following parts.

  • Tension pulley
  • A/C compressor
  • Crankshaft pulley
  • Idle pulley

Legend

  1. Lock nut
  2. Adjust bolt
  3. Idle pulley
  4. A/C compressor drive belt
  5. Idle pulley

2. Except M/T models (Euro 5 or above)

1) Loosen the tension pulley lock nut.

2) Loosen the tension pulley adjust bolt.

3) Remove the A/C compressor drive belt from the following parts.

  • Tension pulley
  • A/C compressor
  • Crankshaft pulley

Legend

  1. Lock nut
  2. Adjust bolt
  3. A/C compressor drive belt

14. Cooling fan belt removal

1) Loosen the tension pulley lock nut.

2) Loosen the tension pulley adjust bolt.

3) Remove the cooling fan belt from the following parts.

  • Fan pulley
  • Generator
  • Crankshaft pulley

MT models

Legend

  1. Adjust bolt
  2. Cooling fan belt
  3. Lock nut

AT models

Legend

  1. Adjust bolt
  2. Cooling fan belt
  3. Lock nut

15. Cooling fan removal

1) Remove the cooling fan and cooling fan clutch as a set from the water pump.

2) Remove the fan pulley from the water pump.

16. Crankshaft pulley removal

1) Install the special tool to the starter installation section of the rear plate.


SST: 5-8840-0214-0 - crankshaft stopper

2) Remove the crankshaft pulley from the crankshaft.

Caution

  • Do not reuse the crankshaft pulley bolt and washer.

Legend

  1. Bolt
  2. Washer
  3. Crankshaft pulley
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