Timing Belt Replacement

Replacement Interval Guide

Daihatsu recommend the raplacement of the timing belt for the Fourtrak every 60,000 miles although you must take into consideration the service history and the mileage into account.

Special Precautions and Repair Times

The replacement of the timing belt should take between one and two hours. You should disconnect the battery earth lead first. You MUST NOT turn the crankshaft or camshaft when the timing belt has been removed. Remove the glow plugs to ease the turning of the engine. Turn the engine in the normal direction of rotation. Do NOT turn the engine via the camshaft or other sprockets. Observe all the tightening torques. Check deisel injection pump timing after belt replacement.

Removal

  1. Remove auxiliery drive belts, fan and fan pulley.
  2. Turn crankshaft to TDC with No.1 cylinder on compression stroke (1).
  3. Undo and remove crankshaft pulley retaining bolt and pulley.
  4. Remove timing belt cover.
  5. Turn crankshaft clockwise until crankshaft (3), camshaft (4) and injection pump (5) sprocket marks are aligned.
  6. Mark direction of rotation on timing belt.
  7. slacken tensioner bolts Diablo and (7).
  8. Remove guide flange (8) from cranckshaft sprocket.
  9. Remove timing belt.

Installation

  1. Ensure sprocket timing belts are aligned, (3), (4) and (5).
  2. Install belt with yellow lines on belt aligned with sprocket timing marks.
  3. Ensure timing belt at least 2mm from front edge of sprockets.
  4. Insert torque wrench into hexagonal hole in tensioner.
  5. Apply torque of 10 Nm to tensioner in anti-clockwise direction, tighten tensioner bolt.
  6. Turn crankshaft smoothly clockwise until camshaft sprocket mark three teeth past mark on timing case.
  7. Slacken tensioner bolt (7) and repeat operations 4 and 5.
  8. Apply load of 2-2.6 kg on belt between crankshaft and camshaft sprockets at the arrow on first diagram and belt should deflect 1.8mm.
  9. Fit crankshaft pulley and turn crankshaft clockwise two complete turns until timing marks (3), (4) and (5) are aligned.
  10. Recheck belt tensioner and tighten tensioner bolt (6).
  11. If tension is correct, remove pulley and refit crankshaft sprocket guide flange (8) with convex side towards belt.
  12. Install all componants in reverse order of removal.
  13. Tighten crankshaft pulley bolt (11) to 217-235 Nm.