Caution
Before removing covers bring number 1 piston to top dead centre on compression stroke.
Remove
Timing belt covers – see operation "Timing Belt Covers Remove and Install".
Remove
Flange from crankshaft pulley.
Flange from fuel injector pump pulley.
Caution
Before removing timing belt align camshaft and injector pump pulleys with bolt holes in cylinder block (arrowed) then screw a locking bolt (M8 x 40 1.5) through each pulley into cylinder block to lock pulleys.
Do not rotate crankshaft with timing belt removed or piston and valves will be damaged.
Remove
Timing belt tension pulley assembly from timing gear case.
Timing belt from pulleys.
Caution
Do not twist or bend timing belt as damage to core may result.
Do not bend timing belt to less than a 20 mm radius (arrowed).
Keep timing belt away from chemicals oil and daylight.
Leave timing belt in an unstressed attitude.
Install
Timing belt to pulleys with letters on outside of belt readable in direction of engine rotation.
Place timing belt on crankshaft pulley and hold with one hand then pass timing belt round the camshaft pulley idle pulley injection pump pulley.
Ensure that crankshaft timing marks (2) are aligned. If not aligned reposition crankshaft ensuring bolts (1) hold the two pulleys. Refit timing belt tensioner pulley assembly do not tighten pulley securing bolt more than finger tight at this time.
Remove
Two bolts holding pulleys in alignment.
Adjust
Remove bolt securing belt tension adjustment lever and hang spring balance from hole in lever (illustrated).
Apply and maintain a load of 10-12 kg on the balance loosen tensioner pulley centre bolt to apply load to belt retighten tensioner pulley centre bolt.
Turn crankshaft through 45° counter-clockwise to shift belt slackness on to tensioner.
Obtain specified belt tension by once more hanging spring balance on tension adjustment lever maintain load of 10-12 kg loosen tensioner pulley centre bolt to re-apply load to belt retighten tensioner pulley centre bolt 76 Nm.
Caution
Do not turn clockwise while adjusting tension.
Install
Bolt securing belt tension lever to housing.
Flanges to camshaft and injection pump timing pulley – bolts 19 Nm.
Timing belt covers – see operation "Timing Belt Covers Remove and Install".