Timing belt torque settings
 

Can’t find a copy of the green book,
Can anyone tell me the torques for the pulleys, idler and the cam caps? I have made a tool for the rear cam pulley and have the dimensions for the camshaft pulley tool to make.
Not too impressed with the gates water pump, the previous one with a cast impeller looks far better

Unless someone else can reply sooner, I will check a greenbook when I get back to where mine are tomorrow night and post what it says.

I want to say the cam caps are 15 ft-lb or 22 ft-lb, but don't quote on those. Idler is low torque. The cam pulley on the front is 33 ft-lb IIRC? But most of us are in the habit of running that one a little tighter. The rear is 75 ft-lb IIRC. Tricky to achieve without that camshaft pulley tool but sounds like you will have that one by the time you are into it. Then of course the big one is the bolt that secures the timing gear and pulley to the front of the crankshaft. About 350 ft-lb on that one using the special tools. Your timing belt kit might have come with a listing of torque values also?

We need to find a good link to electronic greenbook to post on here. They are out there but I always forget to bookmark.

Agreed about the water pump. Maybe you want to find a better replacement? The ones with the nice cast steel impeller are available if you look for them. Maybe try Hepu, Geba, Graf brands if you do that. Those have been mostly consistent (so far!) for the cast impeller. There are ones out there with plastic impellers also though -- watch out for those.

Correct values above! I checked the 1982 Turbo-D manual to confirm (Section2):
 

Torque as per the Greenbook d24t manual for 1982:

Vibration damper front 4 inhex bolts: 20Nm=15ft.lbs
Camshaft caps 20Nm=15ft.lbs
Cooling fan bolts 9Nm=7ft.lbs
Vibration damper center bolt 350Nm=255ft.lbs if wrench 5188 is used and wrench must be in line with wrench 5188.
Camshaft front 45Nm=33ft.lbs
Camshaft rear 100Nm=73ft.lbs
Injection pump center bolt between the six hardpipes on the `head` : 9Nm=6.5ft.lbs
Intake manifold 25Nm=18ft.lbs
Injectors 70Nm=50ft.lbs
DELIVERY PIPES: 25Nm=18ft/lbs (or could do even less as per your own judgement)
Flywheel/carrier plate bolts 75Nm=55ft.lbs
Turbine housing 20Nm=14ft.lbs
Compressor housing 18Nm=13ft.lbs
Turbo to exh manifold 60Nm=43ft.lbs
Main bearing caps 65Nm=48ft.lbs
Connecting rod b caps with new nuts 45Nm=33ft.lbs


Waterpump = ?

Thanks guys that will keep me going tomorrow, get the cam timing side done.
Cursing the guy who polished up my engine and made it look good previously he’s got me cleaning and painting cam belt covers instead of throwing it back together!
I was going to reuse the old pump as it was ok but the o ring was shot and the new one has a wider groove and o ring, I can’t afford to wait on a new pump being Christmas and post being terrible so il run it and see how it goes, not a huge job to swap it now i know my way around it.

Hmm I wonder if the camshaft cap tq. specs are different for hydraulic tappets head. Basher, is yours hydraulic?

Yeah mine is a rarity I think, hydraulic tappers and old style belt

Thanks for the help, she’s up and running again, set the pump to around .88 so I’ve lost some poke but also a lot of smoke.
Going to fit new injector nozzles next and then probably adjust the pump again.
Managed to blow my glow plug relay turning it over and the wire earthed out, so look like an idiot with the bonnet up and a single jump lead when it’s cold, that’s on order now.

Good work!

Depending on which wire earthed out, it might have blown the fuse. IIRC, isn't it a flat copper bar mounted in behind the relay? Have to check.

Also, there's a common blade fuse in the fuse panel that protects the low current side of the GP control circuit.

There was smoke rising from the relay, may check the fuse behind, thanks

Got my brother to check the relay fuse, you just saved me £50!