Timing Belt: Service and Repair

FRONT
Removal
1. With engine removed from vehicle, remove front timing belt upper cover bolts, then the upper cover.
2. Install flywheel holding tool T84P-6375 or equivalent onto flywheel.
3. Remove crankshaft pulley to crankshaft sprocket bolts.
4. Using tool Nos. T58P-6316 and T74P-6700B or equivalents, remove crankshaft pulley.
5. Remove front timing belt lower cover bolts, then the lower cover. Loosen tensioner pulley, then remove timing belt.

Fig. 14 Front timing belt installation:

Fig. 15 Crankshaft pulley timing marks:

Fig. 16 Front timing belt tensioner spring installation:

Installation
1. Align camshaft sprocket with timing marks as shown in Fig. 14. Ensure crankshaft sprocket timing marks are aligned, Fig. 15.
2. Remove tensioner spring from front timing belt upper cover, then install spring into tensioner lever slot and over crankcase stud, Fig. 16.
3. Push tensioner lever toward water pump and tighten lock bolt.
4. Install timing belt as shown in Fig. 14. Adjust timing belt as described in ``Front Timing Belt, Adjust''.
5. Install front timing belt lower cover. Torque lower cover bolts to 5---7 ft. lbs.
6. Install crankshaft pulley. Torque pulley bolts to 17---24 ft. lbs.
7. Install front timing belt upper cover. Torque upper cover bolts to 5---7 ft. lbs.

Fig. 17 Flywheel timing marks:

Fig. 18 Camshaft and injection pump timing marks:

Fig. 19 Loosening tensioner pulley:

Fig. 20 Rear timing belt tensioner:

REAR
1. With engine removed from vehicle, remove rear timing belt cover bolts, then the rear cover.
2. Remove flywheel timing mark cover from clutch housing.
3. Rotate crankshaft until flywheel timing mark is at TDC on No. 1 cylinder, Fig. 17. Ensure injection pump and camshaft sprocket timing marks are aligned with their marks, Fig. 18.
4. Loosen tensioner locknut. Using a suitable tool, insert tool into tensioner slot, Fig. 19. Rotate tensioner clockwise, then tighten locknut.
5. Remove rear timing belt.
6. Install rear timing belt as shown in Fig. 20.
7. Loosen tensioner locknut and adjust timing belt as described under ``Rear Timing Belt, Adjust''.
8. Install rear timing belt cover. Torque the 6 mm rear cover bolts to 5---9 ft. lbs., torque the 8 mm rear cover bolts to 12---16 ft. lbs.