[11C] ENGINE MECHANICAL <4G6-DOHC> - - TIMING BELT - REMOVAL AND INSTALLATION | PRINT PAGE / INDEX / PRIOR / NEXT

TIMING BELT

REMOVAL AND INSTALLATION
Pre-removal Operation Under Cover Removal (Refer to GROUP 51, Under Cover ). Crankshaft Shaft Damper Pulley Removal (Refer to ). Front Axle Crossmember Bar Removal (Refer to GROUP 32, Engine Roll Stopper and Centermember ). Front Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler ). Starter Assembly Removal (Refer to GROUP 16, Starter Motor Assembly ). | Post-installation Operation Starter Assembly Installation (Refer to GROUP 16, Starter Motor Assembly ). Front Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler ). Front Axle Crossmember Bar Installation (Refer to GROUP 32, Engine Roll Stopper and Centermember ). Crankshaft Shaft Damper Pulley Installation (Refer to ). Drive Belt Tension Check (Refer to ). Under Cover Installation (Refer to GROUP 51, Under Cover ).
|  |  | Removal steps
--- | --- | --- | ---
|  | 1. | Crank angle sensor connector
|  | 2. | Timing belt upper cover
|  | 3. | Water pump pulley
|  | 4. | Idler pulley
|  | 5. | Auto-tensioner
|  | 6. | Timing belt lower cover
|  | • | Engine mounting insulator (Refer to GROUP 32, Engine Mount ).
| >>G<< | • | Valve timing belt tension adjustment
<<A>> | >>F<< | 7. | Valve timing belt
| >>E<< | 8. | Timing belt tensioner pulley
|  | 9. | Timing belt tensioner arm
| >>D<< | 10. | Timing belt tensioner adjuster
|  |  | Removal steps
--- | --- | --- | ---
|  | 11. | Power steering oil pressure switch connector
<<B>> |  | 12. | Power steering oil pump assembly
|  | 13. | A/C compressor connector
|  | 14. | Power steering oil pump bracket
|  | 15. | Timing belt idler pulley
|  | 16. | Crank angle sensor
<<C>> | >>C<< | 17. | Crankshaft camshaft drive sprocket
| >>C<< | 18. | Crankshaft angle sensing blade
| >>B<< | • | Balancer timing belt tension adjustment
| >>A<< | 19. | Balancer timing belt tensioner
<<D>> | >>A<< | 20. | Balancer timing belt
| REMOVAL SERVICE POINTS
| <<A>> VALVE TIMING BELT REMOVAL CAUTION Never turn the crankshaft anti-clockwise.
| Turn the crankshaft clockwise, align each timing mark to set No. 1 cylinder to TDC of its compression stroke.
| Remove the timing belt under cover rubber plug and then set the special tool adjusting bolt (MD998738). CAUTION The special tool can be gradually installed at a rate of a 30 degree turn per second. If it is screwed in all at once, the timing belt tensioner adjuster rod will not easily retract and the special tool may bend.
| Screw in the special tool until it comes in contact with the timing belt tensioner arm.
| Gradually screw in the special tool. Then align the timing belt tensioner adjuster rod set hole A with the timing belt tensioner adjustor cylinder set hole B.
| Insert a wire or pin in the set hole. CAUTION To reuse the valve timing belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk. After removal of adjusting bolt special tool, loosen the timing belt tensioner pulley mounting bolt and remove the valve timing belt.
| <<B>> POWER STEERING OIL PUMP ASSEMBLY REMOVAL With the hose installed, remove the power steering oil pump assembly from the bracket. NOTE: Secure the removed power steering oil pump assembly with cord or rope at a position where they will not interfere with the removal of the balancer timing belt.
| <<C>> CRANKSHAFT CAMSHAFT DRIVE SPROCKET REMOVAL
| Use the following special tools to support the crankshaft camshaft drive sprocket. Special spanner (MB991367) Pin (MB991385) Loosen the crankshaft pulley centre bolt and remove the crankshaft camshaft drive sprocket.
| <<D>> BALANCER TIMING BELT REMOVAL CAUTION To reuse the balancer timing belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk.
| INSTALLATION SERVICE POINTS
| >>A<< BALANCER TIMING BELT/BALANCER TIMING BELT TENSIONER INSTALLATION
| Ensure that the crankshaft balancershaft drive sprocket timing marks and balancershaft sprocket timing marks are aligned. Install the balancer timing belt on the crankshaft balancershaft drive sprocket and balancershaft sprocket. There should be no slack on the tension side.
| Assemble and temporarily fix the centre of the pulley of the balancer timing belt tensioner so that it is at the top left from the centre of the mounting bolt, and the pulley flange is at the front-side of the engine. Adjust the balancer timing belt tension.
| >>B<< BALANCER TIMING BELT TENSION ADJUSTMENT CAUTION When tightening the mounting bolt, ensure that the tensioner does not rotate with the bolt. Allowing it to rotate with the bolt can cause excessive tension of the belt.
| With your fingers, lift the balancer timing belt tensioner in the direction of the arrow. Apply pressure of 3.0 ± 0.4 N·m to the balancer timing belt. Tighten the assembling bolt to the specified torque. Then, fix the balancer timing belt tensioner. Tightening torque: 19 ± 3 N·m
| Turn the crankshaft clockwise two turns to set No. 1 cylinder to TDC of its compression stroke and check that the sprocket timing marks are aligned.
| Apply a pressure of approximately 100N at the centre (arrow area) between the sprocket as shown, then inspect whether the belt deflection is within the standard value. Standard value: At adjustment: 5 - 7 mm At replacement: 5 - 7 mm If not within the standard value, adjust the belt tension again.
| >>C<< CRANKSHAFT ANGLE SENSING BLADE/CRANKSHAFT CAMSHAFT DRIVE SPROCKET INSTALLATION
| Clean or degrease the crankshaft, the crankshaft angle sensing blade, the crankshaft camshaft drive sprocket and crankshaft pulley washer as shown. NOTE: Also clean the degreased surfaces. Install the crankshaft angle sensing blade and crankshaft camshaft drive sprocket in the direction shown. Place the larger chamfer side of the crank shaft pulley washer in the direction shown and then assemble on the crankshaft pulley centre bolt. Apply some engine oil to the crankshaft pulley centre bolt bearing surface and screw.
| Use the following special tool as during removal to support the crankshaft camshaft drive sprocket. Special spanner (MB991367) Pin (MB991385) Tighten the crankshaft pulley centre bolts to the specified torque. Tightening torque: 167 N·m
| >>D<< TIMING BELT TENSIONER ADJUSTER INSTALLATION Install according to the following procedures when the timing belt tensioner adjuster rod is fully extended. CAUTION If the compression is too fast, the procedure may damage the rod.
| Slowly compress the timing belt tensioner adjuster rod using a press or vice, then align the set hole A of the rod with set hole B of the timing belt tensioner adjuster cylinder.
| Insert a wire or pin into the aligned set hole. NOTE: When replacing the timing belt tensioner adjuster with new parts, the timing belt tensioner adjuster is set with a pin. Assemble the timing belt tensioner adjuster to the engine, then tighten the assembling bolt to the specified torque. Do not remove the wire or pin until the tension of the valve timing belt is adjusted. Tightening torque: 23 ± 3 N·m
| >>E<< TIMING BELT TENSIONER PULLEY INSTALLATION
| Temporarily tighten the timing belt tensioner pulley as shown.
| >>F<< VALVE TIMING BELT INSTALLATION
| Align the timing marks on the camshaft sprocket, crankshaft camshaft drive sprocket and engine oil pump sprocket.
| Adjust the timing mark of the engine oil pump sprocket. Unplug the cylinder block plug. Insert a bolt (M6 sectional width 10 mm, minor diameter 45 mm) from the plug hole and then check. If the bolt comes in contact with the balancer shaft turn the sprocket one rotation. Re-adjust the timing mark and then check to see that the bolt fits. Do not remove the bolt until the valve timing belt is assembled. Install the valve timing belt as follows:
| Pass the valve timing belt around the crankshaft camshaft drive sprocket, the engine oil pump sprocket and the timing belt idler pulley in that order.
| Pass the valve timing belt around the exhaust-side camshaft sprocket, and hold the valve timing belt with paper clip.
| Use two wrenches to align the timing mark on the rocker cover with that on the camshaft sprocket. Pass the valve timing belt around the inlet-side camshaft sprocket.
| Hold the valve timing belt with paper clips. Pass the valve timing belt around the timing belt tensioner pulley. CAUTION Incorporate the valve timing belt. Then apply reverse rotation (anti-clockwise rotation) pressure to the cam shaft sprocket. Re-check to see that each timing mark is aligned while the tension side of the belt is tight. Remove the two paper clips.
| Turn the timing belt tensioner in the direction shown using special tool tensioner wrench (MD998767) to apply tension to the valve timing belt. Then pre-tighten the timing belt tensioner pulley. Check that the timing marks are aligned.
| Remove the bolt inserted in Step 2 above, then assemble the cylinder block plug. Tighten the cylinder block plug to the specified torque. Tightening torque: 30 ± 3 N·m Adjust the valve timing belt tension.
| >>G<< VALVE TIMING BELT TENSION ADJUSTMENT
| Set special tool adjusting bolt (MD998738) when removing the valve timing belt. CAUTION Always screw in special tool by hand, since use of a spanner or other tools may damage the wire or pin inserted in the timing belt tensioner adjuster. Gradually screw in special tool until the wire or pin inserted in the timing belt tensioner adjuster lightly moves. Turn the crankshaft 1/4 turn anti-clockwise. Turn the crankshaft in the clockwise direction until you align each timing mark to set No. 1 cylinder to TDC of its compression stroke. Loosen the timing belt tensioner pulley mounting bolt. CAUTION When tightening the mounting bolt, ensure that the timing belt tensioner pulley does not rotate with the bolt. Allowing it to rotate with the bolt can cause deficient tension of the belt.
| With special tool tensioner wrench (MD998767) and torque wrench, apply tension torque 3.5 N·m, and tighten the timing belt tensioner pulley mounting bolt to the specified torque. Tightening torque: 48 ± 5 N·m
| Remove wire or pin inserted to timing belt tensioner.
| Remove the special tool adjusting bolt (MD998738), and install the rubber plug to the timing belt under cover. Rotate the crankshaft clockwise two turns, and leave it for about 15 minutes.
| Insert wire or pin removed in Step 7 again, and ensure that it can be pulled out easily. When wire or pin can be easily removed, appropriate tension is applied on timing belt. In this case, remove wire or pin.
| If the projection of timing belt tensioner adjuster rod is within the standard value, appropriate tension is applied. Standard value (A): 3.8 - 4.5 mm If wire or pin cannot be easily pulled out, repeat Step 1 through Step 9 to reach proper valve timing belt tension. CAUTION Always check the tightening torque of the crank shaft pulley centre bolt when turning the crack shaft pulley centre bolt anti-clockwise. Re-tighten if it is loose.
| Check again that the timing marks on sprockets are aligned.

[11C] ENGINE MECHANICAL <4G6-DOHC> - - TIMING BELT - REMOVAL AND INSTALLATION | PRINT PAGE / INDEX / PRIOR / NEXT

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