Timing Belt: Service and Repair

Fig. 12 Timing mark locations on damper pulley:

Fig. 13 Injection pump pulley alignment:

Fig. 14 Fixing injection pump pulley with lock bolt:

Fig. 15 Fixing camshaft in place with tool No. J-29761:

1. Disconnect battery ground cable.
2. Remove undercover 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.
6. Bring cylinder No. 1 to TDC, Fig. 12, ensure that setting mark on injection pump pulley is in alignment with front plate, then fix the pulley with 8 mm 1.25 pitch bolt, Fig. 13 and Fig. 14.
7. Remove cam cover and loosen valve adjustment screws so rocker arms are in a free state. Fix camshaft by installing fixing plate, tool No. J-29761, into the slit in rear end of the camshaft, Fig. 15.

Fig. 16 Timing belt holder:

Fig. 17 Timing belt installation sequence:

Fig. 18 Semi-tightening sequence of tension pulley:

Fig. 19 Torquing tension pulley bolt sequence:

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.
11. Install new timing belt using sequence shown in Fig. 17. Ensure that belt cogs are properly installed in pulleys. Do not disturb crankshaft setting.
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. 18.
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 should fit smoothly into the rear slit of the camshaft. Remove plate.
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. 19. Torque bolts 1 and 2 to 11 to 18 ft. lbs. and bolt 3 to 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. Adjust valves. Refer to ``Valves, Adjust'' for procedure.
21. Reverse steps 1 through 8 to reassemble.