After only 3 wks of owning a Townie SuperExtra 2.0TD '93 model, I thought I would replace the 4 pulley belts that came with it. All came off fine except the air con belt, which I noticed that the main crank pulley was rubbing on air con belt tensioner pulley and also noticed it was misaligned. Tried to remove main crank pulley. The bolt started to come out but then locked up and now won't retighten, so pulley is now loose. Bolt seized, need help! Please! Is there anything stopping it coming out??? - (#290) Barry Powell, 14 Jun 01

I have a 92 2.0 TD Lite Ace and had a similar problem with a loose Crankshaft pulley. Local Toyota dealer indicated that their records show a number of Crankshaft pulleys had been ordered in the UK recently so it must be a relatively common problem! See this site for the history ( chop chop Crankshaft pulley ).
To remove the Air Con belt loosen the centre bolt in the tensioner pulley( 12 or 14mm spanner? ) then slacken the tensioner bolt underneath. Remove the Air Con belt.This will allow you to better remove the Crankshaft pulley. If it feels partially seized you need to lock the Crankshaft pulley to prevent the crankshaft turning. OK if its a manual - put it in gear, that will help but not guarantee it. You may have to resort to putting a spanner/short screwdriver/bar between the spokes of the pulley and the sump/block to prevent the crankshaft turning. Then loosen the crankshaft nut 19mm I think. Obviously you should not use EXCESSIVE force. Careful removing the Crankshaft pulley so the key does'nt fall inside the timing cover. I don't believe the clearance actually allows this to happen. Check the machined groove in the pulley to ensure it's not damaged or that the key has not turned in it. If it is damaged, replace the pulley!( Circa 200 quid- I did! )If it's not damaged get a new bolt- about 2 pounds 50 pence. Get a new key at about 70P. When replacing the pulley and nut I recommend you use a good quality threadlock compound ( Loctite )to ensure this will not happen again. There are probably torque values that the pulley needs to be pulled down to, David Millar should be able to help you with this.
Hope this helps. - (#292) Stephen Judge, 14 Jun 01

PS response. No I believe there is nothing that should stop the bolt coming out unless there has been an excesive ammount of threadlock compound applied to it previously. On removing mine I had evidence on the threads of the bolt of a considerable amount. - (#293) stephen Judge, 14 Jun 01

Thanks Stephen for the advice, I would have sworn there was a locking nut on the other end it was that tight. Eventually I soaked it in WD40 overnight then made up a piece of flat bar to lock up the pulley, got a ratchet with an extension tube on and slowly it came out. My wife insists she sent it psychic vibes, but who knows.
It appears the bolt was inserted cross threaded because at least half of the thread was chewed up. Anyway, new bolt and belts and the engine runs quietly again.
Many thanks Barry - (#305) Barry Powell, 16 Jun 01