Removal
1 remove
bell housing lower inspection plate
aux drive belt
crank pulley bolts
crank pulley
timing belt covers
cyl head cover
2 turn crank to TDC on number 1
ensure timing marks aligned on injector pump and flywheel
3 Hold camshaft use a 22mm spanner on flats of cam at number 4 cyl and slacken bolt on camshaft.
4 slacken water pump bolts and turn water pump to release tension on belt
5 undo RH front eng mount from side member and move engine away from sidemember.
6 remove timing belt from sprockets and slip belt between sidemember and engine mounting.
Installation
1 Ensure timing marks aligned at flywheel and injector pump.
2 slide new belt between side member and engine mount and fit to sprockets.
3 fit eng mount to sidemember.
4 this is where you are supposed to use tension gauge but turn water pump clockwise. twist belt between finger and thumb to allow only 1/2 turn quite taut on these but not overtight or will break belt under load.
5 Tighten water pump bolts to 25Nm
6 check timing marks again
7 lightly tighten camshaft sprocket bolt
8 Check valve timing as follows.
*turn crank to 90 degrees before BTDC
*install measuring bar ensure left hand locating pins are posistioned in bores of camshaft housing.
*install dial gauge with foot of dial gauge on base circle of No1 cyl inlet valve cam lobe (2nd lobe from front)
*set dial gauge to zero with measuring foot on cam lobe base circle.
*move measuring bar to left so that right hand locating pins are positioned in bores of camshaft housing and dial gauge foot is over cam lobe.
* turn crank clockwise until TDC marks aligned on inj pump and flywheel.
* dial gauge should indicate 0.55 + or - 0.03mm
There is a procedure to follow if it doesn't measure this. If you want this and detailed diagrams let me know your email address and I will email them to you.
chris
December 2005
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