Timing Belt: Adjustments
Basic setting of engineSpecial tools: 5190, 5193, 5194, 5197, 5799, 5201
The following operations are described in this section:
- setting camshaft position in relation to crankshaft
- setting tension of drive belts (front and rear)
- injection timing.
Engines should be basic-set if, by adjusting the pump, it is not possible to obtain the correct injection timing. (Camshaft setting may have changed.)
Remove:
- Valve cover
- timing gear covers (front and rear).
Turn engine until cyl. 1 is at TDC - injection
Always use the vibration damper center bolt to turn the engine.
27 mm socket or wrench 5188.
Both cylinder 1 cams should point obliquely upwards.
Flywheel at 0 mark.
Lift off pump belt
Slacken mounting bolts for injection pump bracket to release belt tension. Tighten one bolt so that pump remains in upper position.
Lift off belt.
Remove camshaft rear sprocket
Hold sprocket in position with 5199 and unscrew nut with wrench 5201. Take care not to rotate camshaft.
Slacken camshaft front sprocket
Use 5199 to hold sprocket in position when loosening bolt. Make sure that camshaft does not rotate.
Tap sprocket to free it from camshaft.
Set belt tension
Adjust tension by moving coolant pump.
Use gauge 5197 to check belt tension. Attach gauge to belt and set to 12.5 units.
Stretch belt until mark on gauge plunger is flush with sleeve.
Depress belt strongly with hand and recheck/adjust tension.
Set camshaft position
Place gauge 5190 at rear of camshaft. Insert a 0.2 mm (0.008 in) feeler gauge beneath left side of gauge to compensate for timing gear clearance.
Camshaft is now set at correct position.
Make sure cyl. no.1 is at top dead center
Check 0 mark on flywheel and adjust if necessary.
Tighten camshaft front sprocket
Use 5199 to prevent sprocket from turning. Make sure that camshaft does not turn.
Torque center bolt to 45 Nm (33 ft lbs).
Remove gauge 5190 and feeler gauge
Disconnect cold start device
Slacken screw 1. Push lever forward and rotate sleeve 900. Note Do not turn screw 2 otherwise it will be necessary to remove cold start device and reset it on a test bench.
Basic-set injection pump
Slacken pump mounting bolts (Allen key = 6 mm). Align marks in pump and mounting bracket by turning pump. Retighten mounting bolts.
Set dial indicator zero. Lock pump gear at cyl. 1 injection using stop 5193
Unscrew and remove plug from injection pump distributor. Install holder5l94 and dial indicator (range ~3 mm). Set gauge to approx. 2 mm.
Turn pump gear clockwise until mark on gear and mounting bracket coincide.
Then turn pump gear back slightly until mm. reading registers on dial indicator.
Set indicator to zero.
Turn pump gear clockwise until mark on gear and pump mounting bracket coincide. Lock gear in this position with stop 5193. (Insert stop through pump gear into mounting bracket.)
Install camshaft rear sprocket and belt -
Tighten center bolt by hand, but it should still he possible to turn sprocket on camshaft.
Set belt tension
Adjust tension by moving pump.
Use gauge 5197 to check belt tension. Attach gauge to belt and set to 12.5 units.
Stretch belt until mark on gauge plunger is flush with sleeve.
Depress belt strongly with hand and recheck/adjust tension.
Set pump and tighten camshaft rear sprocket
Use 5199 to hold sprocket. Torque wrench should be at right angle to wrench 5201 otherwise torque will be incorrect.
Using 5199, turn sprocket slowly clockwise until dial indicator shows: 0.85 mm (0.0335 in)
Hold sprocket in this position and torque bolt to 100 Nm (73 ft. lbs). Take care that camshaft and sprocket do not move.
Remove stop 5193 from pump gear