Timing Belt: Service and Repair

Fig. 16 Crankshaft pulley at TDC:

Fig. 17 Belt tensioner spring removal:

Fig. 18 Belt tensioner pulley nut removal:

1. Disconnect battery ground cable.
2. Remove timing pulley housing covers. Refer to ``Timing Pulley Housing Cover, Replace'' for procedure.
3. Remove injection pump timing pulley flange retaining bolts.
4. Remove tension spring, Fig. 17. When removing tension spring, use care to avoid distorting spring.
5. Remove tension pulley nut, Fig. 18, then the pulley and tension center.
6. Remove timing belt. Avoid twisting or kinking belt. Keep the belt free of water, oil, dust and other foreign material.
7. Ensure crankshaft pulley TDC mark is still aligned with timing pointer, Fig. 16.

Fig. 19 Pulley alignment:

Fig. 20 Belt tensioner installation:

Fig. 21 Crankshaft hub positioning:

8. Rotate injection pump timing pulley and camshaft timing pulley as necessary to bring them into alignment, Fig. 19.
9. Install timing belt over crankshaft timing pulley, then the camshaft timing pulley and the injection timing pulley.
10. Install tension center and tension pulley. Ensure tension center end is in proper contact with two pins on timing pulley housing, Fig. 20.
11. Loosely install tension pulley nut, then install tension pulley spring.
12. Semi-tighten tension pulley nut.
13. Rotate crankshaft two complete revolutions in normal direction of rotation to seat timing belt, then rotate an additional 90° beyond TDC to settle injection pump, Fig. 21. Do not attempt to rotate crankshaft in opposite direction of normal crankshaft rotation.
14. Loosen tension pulley nut, allowing the tension pulley assembly to take up belt slack. Torque tension pulley nut to 78-95 ft. lbs.
15. Install injection pump pulley flange. The hole in the flange outer circumference should be aligned with injection pump timing mark.

Fig. 22 Injection pump & camshaft pulley alignment:

Fig. 23 Measuring belt tension:

16. Again rotate engine in normal direction of rotation and bring cylinder No. 1 to TDC on compression stroke. Check injection pump and camshaft pulley alignment marks to ensure proper installation, Fig. 22.
17. Check timing belt tension between crankshaft and injection pump pulley with tool J-29771, Fig. 23. Tension should be 213-356 psi.
18. Install upper and lower timing pulley housing covers.
19. Install crankshaft pulley and drive belts.