TIMING BELT ASSEMBLY [WITHOUT DIESEL PARTICULATE FILTER]

1. Assemble in the order indicated in the table.

Seal Plate Assembly Note

1. Install the seal plate and hand tighten the bolts in the order A to B.

2. Tighten the bolts in the order shown.

Camshaft Pulley Assembly Note

1. Hold the camshaft using the SST.

Gear Case Assembly Note

1. Apply silicone sealant as shown in the figure.

Thickness

1.5-2.5 mm {0.059-1.098 in}

2. Tighten the bolts in clockwise order.

Drive Gear Assembly Note

1. Hold the camshaft using the SST.

2. Remove the drive gear lock bolt.

Gear Cover Assembly Note

1. Apply silicone sealant as shown in the figure.

Thickness

1.5-2.5 mm {0.059-1.098 in}

2. Tighten the bolts in clockwise order.

Timing Belt Pulley Assembly Note

1. Hold the crankshaft using the SST.

2. Tighten the timing belt pulley lock bolt.

Injection Pump Pulley Assembly Note

Caution

• To prevent the bolts (M8 x 1.25) from damaging the injection pump and pulley, do not fully tighten the detent bolt. If it contacts the pulley surface, it will damage the pulley.

1. Fix the injection pump pulley to the bracket using two bolts (M8 x 1.25).

Idler Assembly Note

Caution

• The idler has a front and back relative to the engine, therefore when installing make sure that the longer projection of the shaft is on the engine side as indicated in the figure.

Timing Belt, Timing Belt Auto Tensioner Assembly Note

Caution

• Placing the auto tensioner horizontally can cause oil leakage and damage the auto tensioner. Place the auto tensioner vertically when using a vise.

1. Verify the thrust of the auto tensioner rod in the following order:

(1) If the tensioner rod is rigid when it is pushed with a force of approximately 235 N {24 kgf, 53 lbf}, push it down slowly and fix the pin in the hole.

(2) If there is no resistance on the tensioner rod and it moves slightly when it is pushed with a force of approximately 235 N {24 kgf, 53 Ibf};

Caution

• To prevent damage to the inside of the auto tensioner, do not press down the auto tensioner rod with a force greater than the specified 235 N {24 kgf, 53 lbf}.

Be careful that the rod does not touch the bottom.

1) Push it down slowly two or three times to the bottom end of the rod.

2) If the rod protrudes approximately 8.1 mm {0.32 in}, verify that there is resistance on the tensioner rod.

• If the resistance is restored, push it down slowly and fix the pin in the hole. If the resistance is not restored, replace the auto tensioner.

Caution

• To prevent the bolts (M8 x 1.25) from damaging the injection pump and pulley, do not fully tighten the detent bolt. If it contacts the pulley surface, it will damage the pulley.

2. Verify that all timing marks are correctly aligned.

3. Fix the camshaft pulley to the cylinder head using bolt (M8 x 1.25).

4. Fix the injection pump pulley to the bracket using two bolts (M8 x 1.25).

5. If not, align all timing marks according to the following procedure.

Caution

• Turn the crankshaft in the direction which will prevent the TDC and BDC from being passed. Otherwise it can cause the valve and piston to contact.

(1) Turn the crankshaft and set it an angle of 45° or more away from the TDC and BDC.

(2) Align the timing marks of the camshaft pulley.

(3) Align the timing marks of the injection pump pulley.

(4) Turn the crankshaft and align the timing marks of the timing belt pulley.

6. Install the timing belt on the pulleys in the following order.

(1) Timing belt pulley

(2) Idler

(3) Injection pump pulley

(4) Camshaft pulley

(5) Water pump pulley

(6) Tensioner

7. Remove the injection pump pulley fixing bolts and camshaft pulley fixing bolt (M8 x 1.25).

8. Hand-tighten the auto tensioner bolts in the order A to B.

9. Tighten the auto tensioner bolts in the order A to B.

10. Remove the pin from the auto tensioner to apply tension to the belt.

11. Turn the crankshaft clockwise twice, and align the timing marks.

12. Verify that all timing marks are correctly aligned. If not, repeat from Timing Belt, Timing Belt Auto Tensioner Removal Note.

Crankshaft Pulley Assembly Note

1. Hold the crankshaft using the SST.

2. Tighten the bolts in the order shown.