Timing Belt Replacement

The timing belt, water pump, belt tensioner, and idler pulley should be replaced every 6,000 hours. These components are all included in the Timing Belt Kit. The first 6,000 hour timing belt replacement is typically covered under the unit's basic warranty.

Note Replacement is necessary any time oil, fuel, or coolant contaminates the timing belt.

See the following procedure to replace the timing belt and related components. The procedure requires the use of the following tools:

  • Flywheel Locking Tool P/N 204-2971

  • Timing Belt Tool Kit P/N 204-2979 (includes the following)

    • Locator Pin 5 mm P/N 204-2977

    • Locator Pin 8 mm P/N 204-2978

  1. Disconnect the battery from the unit.

  2. Drain the engine cooling system.

  3. Remove the generator belt and A-frame mount from the front of engine.

  4. Remove the top timing cover (four bolts).

    Remove Top Timing Cover

  5. Rotate the crankshaft clockwise using an 18 mm socket to align the camshaft pulley to the pegging position. The pegging position is reached when the hole in the camshaft pulley is aligned with the corresponding hole in the cylinder head. This position is located to the upper right of the axis of the pulley.

    Note Do not turn the engine counter clockwise. If the position is exceeded, do not turn back, turn two crankshaft revolutions, always clockwise until you reach the correct position.

    Rotate Crankshaft Clockwise

    Align Hole in Camshaft Pulley with Corresponding Hole in Cylinder Head

  6. Peg the camshaft pulley using tool P/N 204-2978.

    Place Peg in Camshaft and Cylinder Head

    Note Tool P/N 204-2978 may need to be trimmed so it will fit between the unit frame and the engine. See the picture below. If needed, trim the knurled end of peg.

    Trim Knurled End if Necessary

  7. Remove shield below starter and install a flywheel locking tool P/N 204-2971.

    Flywheel Locking Tool

    Install Flywheel Locking Tool

  8. Remove the crankshaft bolt and pulley, and set aside.

    Remove Crankshaft Bolt

  9. Remove the five bolts, disconnect the wiring harness, and remove the lower timing cover.

    Remove The Lower Timing Cover

  10. Peg the injection pump gear using tool P/N 204-2977.

  11. Remove bolt (8) and the engine speed sensor.

    Peg Injection Pump Gear and Remove Engine Speed Sensor

  12. Remove the top engine bracket.

    Remove Top Engine Bracket

  13. Loosen bolt (13) and remove the belt tensioner.

    Remove Belt Tensioner

  14. Keep the camshaft and injection pump pegs in place and remove the timing belt.

  15. Loosen and remove the timing belt guide roller.

    Remove Belt Guide Roller

  16. Set aside and DO NOT REUSE the following removed parts.

    1. Belt guide roller

    2. Tensioner roller

    3. Timing belt

  17. Install the new belt guide roller. Torque to 27.3 ft-lb (37 N•m).

    Install New Belt Guide Roller

  18. Replace the coolant (water) pump.

    1. Remove the seven bolts that fasten the water pump to the engine.

      Remove Water Pump Bolts

    2. Remove the water pump and gasket.

    3. Install a new gasket and water pump. Torque the bolts in two stages in the order shown below.

      The initial torque should be 3.7 ft-lb (5 N•m).

      The final torque should be 6.6 ft-lb (9 N•m).

      Install New Water Pump

  19. Before installing the new timing belt, check for play in the injection pump shaft (high pressure fuel pump). If injection pump shaft has play, replace the injection pump. Refer to the TKDV6 Repair Manual (TK 55810).

  20. Install the new timing belt. Position the belt, the reference number on the belt should be between the injection pump pulley (iii) and the camshaft pulley (ii).

    1. Start at the crankshaft pulley (0).

    2. From (0) work the belt up and around pulley (i).

    3. Keep Strand C tight and wrap belt around the camshaft pulley (ii).

    4. Next bring the belt down to the injection pump pulley (iii). Keep all slack in the belt between the injection pump pulley (iii) and the water pump (iv).

      Install New Timing Belt

  21. Install the new belt tensioner and finger tighten the bolt.

  22. Remove the shipping key from the belt tensioner.

    Remove Shipping Key from Belt Tensioner

  23. Install the engine speed sensor and tighten the bolt to 5.9 ft-lb (8 N•m).

    Install Engine Speed Sensor

  24. Remove the camshaft and injection pump pin tools.

    Remove Camshaft and Injection Pump Pin Tools

  25. Use an Allen wrench to rotate the tensioner roller counter clockwise until Pin A is centered with Area B.

    Rotate Tensioner Roller Counter Clockwise until Pin A Is Centered with Area B

  26. While holding Allen wrench with Pin A centered in Area B. Tighten the bolt to secure the tensioner to engine block. Torque the tensioner bolt to 22.1 ft-lb (30 N•m).

  27. Place the crankshaft pulley onto the crankshaft.

    Note Be sure to align the input print on the back of the crankshaft pulley with the key in the crankshaft.

    Input Print on Crankshaft Pulley

    Key in Crankshaft

  28. Install the old crankshaft bolt. DO NOT tighten at this time.

  29. Remove the flywheel locking tool.

    Remove Flywheel Locking Tool

  30. Rotate the crankshaft six turns clockwise.

    Rotate Crankshaft Six Turns Clockwise

  31. Put the engine into the pegging position. Peg the crankshaft with tool P/N 204-2977.

    Peg Crankshaft with Tool P/N 204-2977

  32. Once crankshaft is in pegging position, remove pin P/N 204-2977 and install it at the injection pump pulley. The peg tool should fit into hole in block at the gap in the pulley.

    Install Pin P/N 204-2977 at Injection Pump Pulley

  33. Use pin tool P/N 204-2978 to check the position of the camshaft pulley.

    Use Pin P/N 204-2978 to Check Camshaft Pulley Position

  34. If the camshaft peg hole does not line up, check to make sure the pin is not misaligned by more than 0.04 in. (1 mm).

    Note If the camshaft or injection pump pins do not fit properly go back to step 6 and repeat timing belt procedure. If the camshaft and injection pump are timed correctly remove all pins and proceed to step 35.

  35. Check that the timing belt tension is set correctly. The control pin A must be between these two extreme positions.

    Control Pin A Should Be Between These Positions

  36. If the tensioner needs to be adjusted, place an Allen wrench in the tensioner, loosen the bolt, and adjust it to center control pin A as shown below. Re-torque the tensioner bolt if adjustment was necessary to 22.1 ft-lb (30 N•m).

    Control Pin A in Center Position

  37. Install the engine bracket. Tighten the four bolts to 33.2 ft-lb (45 N•m).

    Install Engine Bracket

  38. Reinstall the flywheel locking tool.

    Reinstall Flywheel Locking Tool

  39. Remove the crankshaft bolt and pulley.

  40. Install the lower timing cover Torque the bolts to 3 ft-lb (4 N•m).

  41. Install the upper timing cover. Torque the bolts to 3 ft-lb (4 N•m).

  42. Install the crankshaft pulley. Make sure to align the input print on the back of the crankshaft pulley with the key in the crankshaft when installing the pulley onto the crankshaft.

  43. Install a NEW crankshaft bolt.

    1. Torque the bolt to 25.8 ft-lb (35 N•m).

      Torque to 25.8 ft-lb (35 N•m)

    2. Tighten the bolt an additional 190 degrees.

      Tighten Bolt 190 Degrees

  44. Remove the flywheel locking tool and reinstall the bolt.

    Remove Flywheel Locking Tool

    1. Torque the bolt to 40.6 ft-lb (55 N•m).

      Torque to 40.6 ft-lb (55 N•m)

  45. Plug the harness into the crankshaft position sensor and clip the harness onto the lower timing cover.

    Install Crankshaft Position Sensor Harness

  46. Reinstall the generator belt and A-frame

  47. Refill the engine cooling system.

  48. Connect the battery and verify proper unit operation.

Parent topic: Engine Maintenance