1. Failure to set belt tension correctly to this procedure will result in premature engine failure! 2. The Auto-tensioner is a thermal expansion compensation device so tensioning should only be carried out after letting the engine cool for a minimum of 3 hours. Allow the engine and tensioner to stabilize to the same relative ambient temperature before installing a tensioner for proper belt tension adjustment. Do not attempt to install a cool tensioner onto a hot engine. 3. Never reuse old belts and always replace both Camshaft and Fuel Injection Pump belts together. Initial Removal of Timing Belt and Tensioner 4. Turn the crankshaft in the normal direction of rotation of the engine (clockwise) until the slot in the injection pump timing belt is at 11 o clock (See Figure 1). 5. Unscrew the blanking plug and insert the crankshaft TDC pin (pt# 21-162B). Make sure TDC pin is fully seated (See Figure 2). 6. Turn the crankshaft carefully until it comes up against the TDC pin (See Figure 2). 7. Undo the Eccentric Idler center bolt and set the idler teardrop to 6 o clock position (See Figure 3). 8. Insert the alignment tool (pt# 21-162B) in the slot on the camshaft and ensure fully home (See Figure 4). 9. Undo the camshaft pulley timing bolt three full revolutions. 10. Free the camshaft timing pulley from the taper by inserting a screwdriver between the pulley and the back plate, and then strike the back plate with a soft metal drift (See Figure 5). 11. Remove cam pulley, tensioner, and camshaft timing belt. Installation of Timing Belt and Tensioner 12. Install new Tensioner torque mounting bolts to manufactures specifications. Route new timing belt around system, Make sure direction arrows on the belt are in the direction of engine rotation and that it is correctly seated. Finish by installing cam-pulley into belt and installing pulley over end of camshaft nose. 13. Lightly oil between the head and the captive washer of the camshaft pulley bolt, finger tighten bolt until it touches the pulley, then back off one quarter turn. Ensure pulley is still free to rotate on camshaft taper. Page 1/8
Belt pre-tensioning and Belt Settlement 14. Lightly oil under head of eccentric idler bolt. Turn idler teardrop to 9 o clock position then torque bolt to 20 Nm (See Figure 6). 15. Torque cam-pulley center bolt to torque 20 Nm while using reaction tool (pt# 15-030A) to stop any movement of the pulley (See Figure 9). 16. Remove Crankshaft TDC pin (pt# 21-104) and camshaft timing plate (pt# 21-162B). 17. Rotate the crankshaft two (2) complete revolutions in the normal direction of engine rotation (clockwise) manually for proper seating of the belt. (This can be achieved with one of the front wheels raised with the engine in gear and manually turning the wheel.) Initial Belt Tensioning 18. Turn the crankshaft in the normal direction of rotation of the engine (clockwise) until the slot in the injection pump timing belt is at 11 o clock (See Figure 1). 19. Insert the crankshaft TDC pin (pt# 21-162B). Make sure TDC pin is fully seated (See Figure 2). 20. Turn the crankshaft carefully until it comes up against the TDC pin (See Figure 2). 21. Undo the Eccentric Idler center bolt through half a turn. 22. Insert the alignment tool (pt# 21-162B) in the slot on the camshaft and ensure fully home (See Figure 4). 23. Undo the camshaft pulley timing bolt three full revolutions. 24. Free the camshaft timing pulley from the taper by inserting a screwdriver between the pulley and the back plate, and then strike the back plate with a soft metal drift (See Figure 5). 25. Finger tighten the camshaft pulley bolt until it touches the pulley, then back off one quarter turn. Ensure pulley is still free to rotate on camshaft taper. 26. Turn eccentric idler clockwise using a Allen key until the auto-tensioner just comes up to the right hand edge of the setting window in a clockwise direction, hand tighten up eccentric idler center bolt. N.B. Pointer will move from right to left as tension is increased in the belt. (use a mirror to achieve a better view of auto tensioner.) See figure 7 and 8. 27. Torque eccentric idler center bolt to 45-55 Nm using Allen key to react against any movement achieved by friction under bolt head. 28. Recheck auto-tensioner pointer position, if between right hand edge of setting window and the center, continue process. If not return to step 26. Page 2/8
29. Torque cam-pulley center bolt to torque (30-36Nm for M8 bolt, 45-55Nm for M10 bolt) while using reaction tool to stop any movement of the pulley. Failure to prevent rotation of the pulley will result in incorrect belt tension (See Figure 9). Final Check, Belt Tensioning 30. Recheck auto-tensioner pointer position, if within window continue process if not within window return to step 23 and continue from that point. Note: Failure to ensure tension is set within window on a cold engine will result in premature engine failure (See Figure 10). 31. Remove Crankshaft TDC pin (pt# 21-104) and camshaft timing plate (pt# 21-162B). 32. Rotate the crankshaft two (2) complete revolutions in the normal direction of engine rotation (clockwise) manually to ensure proper seating of the belt. (This can be achieved with one of the front wheels raised with the engine in gear and manually turning the wheel.) 33. Turn the crankshaft clockwise until the slot in the injection pump timing belt pulley is at 11 o clock (See Figure 1). 34. Insert the crankshaft TDC pin, making sure pin is fully seated (See Figure 2). 35. Turn the crankshaft carefully until it comes up against the TDC pin (See Figure 2). 36. Insert the alignment tool (21-162B) in the slot on the camshaft and ensure fully home (See Figure 4). 37. Recheck auto-tensioner pointer position, if within window continue process (see figure 10), if not within window return to step 23 and continue from that point. Note: Failure to ensure tension is set within window on a cold engine will result in premature engine failure. 38. Remove Crankshaft TDC pin (pt# 21-104) and camshaft timing plate (pt# 21-162B), reinstall blanking plug. 39. Reassemble engine assembly. Page 3/8
Figure 1: Injection pump timing at 11 o clock Figure 2 TDC pin installation Page 4/8
Figure 3: Idler teardrop at 6 o'clock position Figure 4: Installation of alignment tool Page 5/8
Figure 5: Freeing up of camshaft timing pulley Figure 6: Idler teardrop at 9 o clock Page 6/8
Figure 7: eccentric idler adjustment Figure 8: Tensioner initial set position Page 7/8
Figure 9: Torque procedure for cam pulley Figure 10: Final auto-tensioner pointer positio Page 8/8