Timing Belt: Service and Repair

Removal

1. Disconnect battery ground cable.
2. Drain cooling system and remove radiator from vehicle.
3. Remove water pump pulley.
4. Remove crankshaft pulley.
5. Remove A/C idle pulley, if equipped.
6. Remove timing belt cover attaching bolts, then the timing belt cover.
7. Remove timing belt guide and glow plugs.

Fig. 11 Aligning TDC mark on camshaft timing sprocket with top end of cylinder head:

8. Position No. 1 cylinder at TDC of compression stroke and align TDC mark on camshaft timing sprocket with top end of cylinder head, Fig. 11.

Fig. 12 Placing alignment marks on all timing sprockets & timing belt:

9. Remove timing belt and injection pump drive pulley. If original timing belt is to be reused, draw a directional mark (arrow) on the timing belt (in direction of engine rotation) and place alignment marks on all timing sprockets and timing belt as shown in Fig. 12.
10. Remove No. 2 idler pulley and crankshaft timing sprocket.

Installation

1. Install crankshaft timing sprocket and No. 2 idler pulley. Torque idler pulley to 29 ft. lbs.
2. Install injection pump drive pulley. Torque mount nut to 47 ft. lbs.
3. Install camshaft timing sprocket. Torque sprocket retaining bolt to 73 ft. lbs.
4. Install No. 1 idler pulley.

Fig. 13 Aligning timing marks on injection pump drive pulley, camshaft & crankshaft timing sprockets:

5. Position No. 1 cylinder at TDC of compression stroke and align timing sprocket and drive pulley at each position. If original timing belt is reused, align marks on the injection pump drive pulley, Fig. 13. Mark on injection pump drive pulley should be at a slightly retarded position.
6. Install timing belt onto engine.
7. If installing a new timing belt, proceed as follows:
a. Install timing belt onto camshaft timing sprocket.

Fig. 14 Aligning marks on injection drive pulley:

b. Align marks on the injection pump drive pulley, Fig. 14.
c. Install timing belt onto No. 2 idler pulley and crankshaft timing sprocket.
8. If installing original timing belt, proceed as follows:

Fig. 12 Placing alignment marks on all timing sprockets & timing belt:

a. Align points marked during removal, Fig. 12 and install timing belt with arrow pointing in direction of engine rotation.
b. Ensure timing belt is completely meshed with camshaft sprocket, crankshaft sprocket and injection pump drive pulley.
9. Install tension spring.

Fig. 15 Ensuring timing marks are aligned:

10. Check position of timing belt and sprockets by turning crankshaft 2 complete revolutions from TDC to TDC. Ensure each sprocket aligns with timing marks, Fig. 15.
11. Torque idler pulley mounting bolts to 14 ft. lbs. While torquing mounting bolts, do not turn idler pulley bracket.
12. Install glow plugs and current sensor.
13. Install timing belt guide and timing belt cover.
14. Install A/C idler pulley, if equipped.
15. Install crankshaft pulley. Torque pulley retaining bolt to 102 ft. lbs.
16. Install water pump pulley and radiator.