REMOVAL & INSTALLATION
1L, 2L and 2L-T Engines
See Figures 1 and 2
The diesel timing belt may be removed by following Steps 1-8, then 15-18 of the Cylinder Head Removal & Installation procedure. To install the belt.
- Temporarily install the idler pulley and check that the pulley bracket can be moved to the left and right by hand.
- Align each timing gear according to the accompanying illustration. Note that the injection pump gear is positioned in a slightly retarded manner.
- Install the timing belt without altering the position of any timing gear.
- Install the idler pulley spring.
- Temporarily install the crankshaft timing gear center bolt and turn the crankshaft timing gear center bolt and turn the crankshaft exactly two revolutions (clockwise). As you turn the crankshaft, you should notice movement of the idler pulley bracket.
- Each timing gear should now align as shown in the accompanying illustration. Note that the injection pump gear marking should now be aligned with the corresponding diamond mark on the engine.
- Tighten the idler pulley bolts to 1-15 ft. lbs.
- Install the crankshaft belt drive pulley. Dip the pulley retaining bolt in engine oil, install the bolt and tighten to 69-75 ft. lbs. WITHOUT turning the engine.
- Assemble the remaining engine components as detailed in their appropriate sections.
See Figures 3, 4, 5, 6, 7, 8 and 9
- Remove the timing belt covers as previously detailed.
- Draw a directional arrow on the timing belt and matchmark the belt to each of the pulleys. Remove the timing belt guide and then remove the tension spring.
- Loosen the idler pulley bolt and shift it left as far as it will go. Tighten the set bolt and relieve the tension on the timing belt. Remove the belt.
- Remove the crankshaft and camshaft sprocket timing pulleys. Remove the idler pulley.
- Align the groove in the crankshaft pulley with the key on the crankshaft and press the pulley onto the shaft.
- Install the idler pulley. Align the groove on the pulley with the cavity of the oil pump and then force it to the left as far as it will go. Temporarily tighten it to 27 ft. lbs. (37 Nm).
- Position the camshaft pulleys on the camshafts so the match holes in each pulley are in alignment with those on the No. 3 (upper rear) timing cover. Align the pulley matchmark with the one on the cover.
Do not install the match pin. Check that the bolt head is not touching the pulley.
- Install the timing belt around the timing pulleys. If reusing the old belt, make sure the arrow and matchmarks all line up with those made earlier on the pulleys.
- Move the idler pulley to the right as far as it will go. Install the tension spring and then loosen the pulley bolt until the pulley moves lightly with the tension spring force.
- Check the valve timing and belt tension by turning the crankshaft two complete revolutions clockwise. Check that each pulley aligns with its timing marks. Retighten the idler pulley bolt to 27 ft. lbs. (37 Nm).
- Remove the camshaft timing pulley bolts and align the match pin hole with the match pin hole in the camshaft. Install the pin and bolt and tighten to 80 ft. lbs. (108 Nm).
- Remove the crankshaft timing pulley bolt and position the belt guide over the crankshaft pulley so the cupped side is out.
- Install the timing covers as detailed previously.