The 2.2L diesel engine is the only engine covered by this repair guide which uses a timing belt instead of a gear or chain assembly.
REMOVAL & INSTALLATION
See Figures 1, 2, 3, 4, 5 and 6
The following procedure requires the use of the belt tension gauge tool No. J-29771 or equivalent.
- Disconnect the negative battery cable.
- Align the mark on the crankshaft pulley with the timing pointer and remove the crankshaft pulley. Remove the front covers.
- Remove the bolts attaching the injection pump timing pulley flange. Remove the tension spring.
When removing tension spring, avoid using excess force, or distortion of spring will result.
- Remove the timing belt tension pulley-to-engine fixing nut, then the tension pulley and tension center.
- Remove the timing belt. Avoid twisting or kinking the belt and keep it free from water, oil, dust and other foreign matter.
No attempt should be made to readjust belt tension. If the belt has loosened through service of the timing system, it should be replaced with a new one.To install:
- Check that the setting marks on the crank pulley, injection pump timing pulley, and camshaft pulley are in alignment, then install the timing belt in sequence of crankshaft timing pulley, camshaft timing pulley and injection pump timing pulley.
- Make an adjustment, so that belt slackness is taken up by the tension pulley. When installing the timing belt, care should be taken so as not to damage the belt.
- Install the tension center and tension pulley, making certain the end of the tension center is in proper contact with two pins on the timing pulley housing.
- Hand-tighten the nut, so that tension pulley can slide freely.
- Install the tension spring correctly and semi-tighten the tension pulley fixing nut.
- Turn the crankshaft 2 turns in normal direction of rotation to permit seating of the belt. Further rotate the crankshaft 90° beyond TDC to settle the injection pump. Never attempt to turn the crankshaft in reverse direction.
If the engine is turned past the timing marks, keep rotating the engine in the normal direction of rotation until the marks align properly.
- Loosen the tension pulley fixing nut completely, allowing the pulley to take up looseness of the belt. Then, tighten the nut to 78-95 ft. lbs. (106-129 Nm).
- Install the flange on the injection pump pulley. The hole in the outer circumference of the flange should be aligned with the timing mark "triangle" on the injection pump pulley.
- Turn the crankshaft 2 (clockwise) turns to position the No. 1 cylinder on to TDC of it's compression stroke, then check that the "triangle" mark on the timing pulley is in alignment with the hole in the flange.
- The belt tension should be checked at a point between the injection pump pulley and crankshaft pulley using tool No. J-29771 or equivalent, to 33-55 lbs. (45-75 N) as read on the scale.
- Adjust valve clearances and reverse the removal procedures.
- Check the injection timing.