Timing Belt: Service and Repair

Fig. 1 Exploded view of timing belts:

Refer to Fig. 1 and remove parts in numerical order as shown. Perform steps 1 through 4 before starting removal procedure.

Fig. 2 Aligning of timing belt timing marks:

1. Rotate crankshaft until piston of No. 1 cylinder is at top dead center. No. 1 cylinder will be at top dead center when all timing marks are aligned as shown in Fig. 2.
2. Mark timing belts to show direction of rotation for reinstallation.
3. Slightly loosen tensioners for each drive belt and slide toward water pump and secure in this position.

Fig. 3 Preventing silent shaft rotation:

4. Remove two silent shaft sprockets. Hold shafts as shown in Fig. 3 to prevent rotation when loosening sprocket nut and bolt.

Fig. 4 Crankshaft sprocket & flange installation:

Fig. 5 Injection pump sprocket & flange installation:

Fig. 3 Preventing silent shaft rotation:

5. Reverse procedure to install. Install crankshaft sprocket B, flange and sprocket as shown in Fig. 4. Install injection pump sprocket and install flange to injection pump sprocket, Fig. 5. Install spacer on left silent shaft with chamfered end toward oil seal. Tighten silent shaft sprockets nut and bolt with shafts held in position as shown in Fig. 3.
6. Move tensioner B fully toward water pump and secure.

Fig. 6 Timing belt B tension adjustment:

7. Align timing marks of silent shaft sprockets and crankshaft sprocket. Install timing belt B with no slack on tension side. Push down on B belt with finger at point A as in Fig. 6.
8. Place tensioner B against timing belt B so belt has slight spring tension. Tighten tensioner B nut and bolt. Tighten nut first, then bolt.

Fig. 7 Deflection test of timing belt B:

9. Check deflection of timing belt B, Fig. 7. Deflection should be from 0.16 - 0.20 inch.
10. Move tensioner fully toward water pump and secure.

Fig. 8 Timing belt installation & sprocket timing mark alignment:

11. Align timing marks of three sprockets, Fig. 8, and install timing belt. When installing timing belt onto sprocket make sure tension side is not slack. Install belt onto crankshaft sprocket, injection pump sprocket and camshaft sprocket in that order. Reinstall belt in original direction of drive.
12. Loosen tensioner mounting bolts and allow tensioner to apply tension to belt by spring force. Check belt at camshaft sprocket for correct engagement.
13. Torque tensioner mounting bolts. Torque slot side bolt before torquing fulcrum side bolt.
14. Check all timing marks for proper alignment.
15. Rotate crankshaft clockwise through two camshaft teeth. Reverse direction of crankshaft until timing marks are realigned.
16. Check belt deflection halfway between camshaft sprocket and injection pump sprocket. Timing belt deflection should be 0.16 - 0.20 inch.