Timing Belt: Service and Repair
Special tools2065A setting bar
3359 locating pin (engine code AAZ)
2064 lock pin (engine codes 1Z, AHU)
Matra V159 pin wrench or equivalent; e.g. Hazet 2587, US4493
Removing
- Remove ribbed belt.
- Remove ribbed belt tensioning roller (if installed).
- Remove upper toothed bell guard and valve cover.
- Set crankshaft to TDC for cylinder 1 and lock camshaft using 2065A setting bar.
- Center the 2065A setting bar as follows:
- Turn locked camshaft, with setting bar in place, until one end of setting bar touches cylinder head.
- Measure gap at other end of setting bar using feeler gauge.
- Select feeler gauge that is one half of measured gap, and temporarily install between setting bar and cylinder head.
- Turn camshaft so that setting bar is resting against feeler gauge then insert second feeler gauge of same thickness at other end between setting bar and cylinder head.
- Lock injection pump sprocket using lock pin.
Engine code AAZ: 3359 rig pin
Engine codes 1Z, AHU. 2064 lock pin
- Loosen injection pump sprocket mounting bolts -1- (AAZ) or center bolt (1Z, AHU).
- Loosen tensioner roller.
- Remove vibration damper and belt pulley.
- Remove lower toothed belt guard.
- Clearly identify toothed belt running direction using felt marker.
- Remove toothed belt.
Installing belt and adjusting tension (basic setting)
- Make sure that TDC marks on flywheel and references align.
- Loosen camshaft sprocket mounting bolt(s) 1/2-turn.
- Loosen from tapered end of camshaft by very carefully tapping with hammer on soft drift inserted through hole of rear toothed belt guard or by GENTLY hitting sprocket squarely on sprocket teeth using synthetic face hammer.
- Place belt onto toothed belt sprocket/crankshaft, intermediate shaft sprocket, injection pump sprocket and tension roller.
- Note running direction of belt.
- Place camshaft sprocket together with toothed belt and tighten mounting bolts.
- Camshaft sprocket can still be turned.
Note:
Illustration shows engine code 1Z; engine code AAZ is similar.
- Turn tensioner roller to right using Matra Vi 59 pin wrench (or equivalent) until notch and lifting arrow are across from one another.
- Tighten tensioner roller clamp nut. Tightening torque: 20 Nm (15 ft lb)
- Make sure that TDC marks on flywheel and reference are still in alignment.
- Tighten camshaft sprocket mounting boll. Tightening torque: 45 Nm (33 ft lb)
- Tighten injection pump sprocket mounting bolt(s). Tightening torque: 25 Nm (18 ft lb)
- Remove setting bar.
- Remove pin.
- Turn crankshaft twice in direction of rotation and place again at TDC for cylinder 1.
Engine codes 1Z, AHU
- Make sure injection pump sprocket can be locked using 2064 lock pin.