20yrs old.. AC refresh, Cam belt, water pump and tensioners

[Geoff]

My mkiv is just 20years old and the AC has been dead for a few years, Cam belt and other stuff in need of replacement.  After a delivery van bent the front it’s was time to bring it back to pristine. 
Having stripped the bumper off I found all sorts of damage, broken undertray, broken ally strips between the layers on the number, a few I straightened, 3 were beyond repair. I found rust in the radiator rail, leaves get trapped and can not blow out because of the foam sealing the rads in. I’d had a leaking steering fluid cooler pipe a few months ago which I put a temporary rubber pipe over. So what started as a quick refresh has turned into a reasonable job.

1) a lump of rad rail needed to be cut out and I created a repair panel and fitted that

2) as the front was in a thousand pieces it seamed Sean able to try and fix the air conditioning, the condenser was corroded (due to the leaves) so I opted to change it, they are not available in the uk, so summit racing in the USA had a denso 477-0589, it is spot on, every thing fitted 100%, £150 + import 25.  New dryer, new O rings.  Compressor I sent to A C   R LTD £270 for reconditioning.

3) new cam belt and tensioner,  could no get the damper off..   had to buy the service tool and welded a bit of 10x40 to it, wood blocks on the floor with the service tool resting on them, 3/4 22mm and scaffold pole and two of use pulling it came off..  the rest was easy.  Just remember to turn the engine through 2 full turns to make sure the valves don’t hit the head on completion.  Oh, paint the timing marks before taking it all apart and line them up first. Then take it to bits. 
4) new water pump.  I thought I had the correct pump, but the there is a pipe that comes out the back and straight up on my engine, the back plate on mother’s one I purchased came out a 90 degree, so there are 2 types..  be carful.

5) new accessory tensioners pulley. 100mm one was 1mm larger then the Oem. 
6) now we get to the bumpers omg.....

toyota really struggled to get the right bits, still haven’t, needed a new undertray, mine has a active spoiler still to locate, the ally strips in the layers, omg, they have now idea of part numbers.. 

that’s so far, will update as I go 

 

 

 

Edited December 13, 2020 by Geoff (see edit history)