Timing Belt: Service and Repair

1. Disconnect battery ground cable.
2. Remove under cover and drain coolant.
3. Remove fan shroud, alternator belt, cooling fan and water pump pulley.
4. Remove ten bolts securing upper dust cover, remove dust cover.
5. Remove bypass hose.

Fig. 2 Timing mark locations.:

Fig. 10 Timing mark location on damper pulley.:

Fig. 11 Injection pump pulley installation:

Fig. 12 Injection pump pulley installation:

Fig. 3 Fixing plate installation:

7. Remove cam cover and loosen valve adjustment screws so rocker arms are in a free state. Fix the camshaft by installing fixing plate, tool No. J-29761 into the slit in rear end of the camshaft, Fig. 13.

Fig. 14 Timing belt holder:

8. Remove crankshaft damper pulley, lower dust cover and timing belt holder, Fig. 14. Under no circumstances should the crankshaft be disturbed from TDC.
9. Remove tension pulley spring, then loosen tension pulley and plate bolts, remove timing belt.
10. Remove camshaft pulley bolt, using a suitable puller remove camshaft pulley, then reinstall pulley and bolt. Tighten bolt just enough to allow the pulley to be turned smoothly by hand.

Fig. 15 Timing belt installation sequence:

11. Install new timing belt using sequence shown in Fig. 15. Ensure that belt cogs are properly installed in pulleys. Do not disturb crankshaft setting.

Fig. 16 Semi-tightening sequence of tension pulley:

12. Concentrate belt looseness on tension pulley, depress tension pulley with finger and install tension spring. Semi-tighten bolts in numerical sequence 1 and 2 to prevent movement of tension pulley, Fig. 16.
13. Tighten camshaft pulley bolt.
14. Remove injection pump pulley lock bolt and camshaft fixing plate.
15. Install crankshaft damper pulley, ensure No. 1 cylinder is at TDC.
16. Ensure injection pump pulley mark is in alignment with mark on plate and fixing plate fits smoothly into the rear slit of the camshaft. Remove plate.

Fig. 17 Bolt Torque Sequence:

17. Loosen tensioner plate bolts and pulley. Concentrate looseness of belt on tensioner, then tighten the bolts in numerical sequence 1, 2 and 3, Fig. 17. Torque bolts 1 and 2, 11 to 18 ft. lbs. Bolt 3, 47 to 61 ft. lbs.
18. Using a belt tension gauge, check tension between camshaft pulley and injection pump pulley. Tension should be 47 to 64 lbs.
19. Remove crankshaft damper and install timing belt holder.
20. Remove cam cover.
21. Inspect the rocker arm shaft bracket bolts for looseness, retorque as necessary.
22. Bring No. 1 cylinder to TDC on compression stroke.
23. Adjust valve clearances of cylinder No. 1, intake valve of No. 2 and exhaust valve of No. 3. Turn crankshaft one full revolution to bring cylinder No. 4 TDC on compression stroke. Adjust clearances of cylinder No. 4, exhaust valve of No. 2 and intake valve of No. 3.
24. Reinstall cam cover.
25. Reverse steps 1 through 19 to reassemble.