Pre-removal Operation
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Post-installation Operation
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| Removal steps |
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|---|---|---|---|
| 1. |
Control wiring harness connection |
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| 2. |
Battery wiring harness connection |
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| 3. |
Connector bracket |
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| • |
Engine mounting insulator (Refer to GROUP 32, Engine Mount  ). |
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| 4. |
Harness bracket |
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| 5. |
Timing belt upper cover |
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| 6. |
Water pump pulley |
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| 7. |
Idler pulley |
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| 8. |
Auto-tensioner |
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| 9. |
Timing belt lower cover |
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>>G<< |
• |
Valve timing belt tension adjustment (Installation only) |
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| <<A>> |
>>F<< |
10. |
Valve timing belt |
| >>E<< |
11. |
Timing belt tensioner pulley |
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| 12. |
Timing belt tensioner arm |
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| >>D<< |
13. |
Timing belt tensioner adjuster |
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| Removal steps |
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|---|---|---|---|
| 14. |
Timing belt Idler pulley |
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| 15. |
Timing belt lower cover bracket |
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| 16. |
Crank angle sensor |
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| <<B>> |
>>C<< |
17. |
Crankshaft pulley centre bolt |
| <<B>> |
>>C<< |
18. |
Crankshaft pulley washer |
| <<B>> |
>>C<< |
19. |
Crankshaft camshaft drive sprocket |
| >>C<< |
20. |
Crankshaft angle sensing blade |
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| >>B<< |
• |
Balancer timing belt tension adjustment (Installation only) |
|
| >>A<< |
21. |
Balancer timing belt tensioner |
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| <<C>> |
>>A<< |
22. |
Balancer timing belt |
REMOVAL SERVICE POINTS
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- 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 special tool adjusting bolt (MD998738).
)
- Screw in the special tool with hands until it contacts the timing belt tensioner arm.
CAUTION)
- Gradually screw in the special tool and then align the timing belt tensioner adjuster rod set hole A with the timing belt tensioner adjuster cylinder set hole B.
)
- Insert a wire or pin in the set hole aligned.
- After removal of the special tool, loosen the timing belt tensioner pulley mounting bolts and remove the valve timing belt.
CAUTION)
- Use the following special tools to hold the crankshaft camshaft drive sprocket.
- Special spanner (MB991367)
- Pin (MB991385)
- Loosen the crankshaft pulley centre bolt and remove the crankshaft pulley washer and crankshaft camshaft drive sprocket.
INSTALLATION SERVICE POINTS
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- Ensure that the crankshaft balancer shaft drive sprocket timing marks and balancer shaft sprocket timing marks are aligned.
- Install the balancer timing belt on the crankshaft balancer shaft drive sprocket and balancer shaft 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 assembling bolt, and the pulley flange is at the front-side of the engine.
- Adjust the balancer timing belt tension.
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- Lift with your fingers the balancer timing belt tensioner in the direction of the arrow. Apply a tensile torque of 3.0 ± 0.4 N·m to the balancer timing belt so the belt is tense without any looseness. Tighten the assembling bolt to the specified torque in this state. Then, fix the balancer timing belt tensioner.
Tightening torque: 19 ±
3 N·m
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- Turn the crankshaft clockwise two turns to set No.1 cylinder to TDC of its compression stroke and check that sprocket timing marks are aligned.
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- Apply a pressure of approximately 100 N at the centre (arrow area) between the sprocket as shown in the figure, then inspect whether the belt deflection is within the standard value.
- <When adjusting> 5 - 7 mm
- <When replacing> 5 - 7 mm
Standard value:
- If not within the standard value, adjust the belt tension again.
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- 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 crankshaft pulley washer in the direction shown in the Figure and then assemble on the crankshaft pulley centre bolt.
- Apply a small of engine oil to the crankshaft pulley centre bolt bearing surface and screw.
- Use the following special tool as during removal to hold the crankshaft camshaft drive sprocket.
- Special spanner (MB991367)
- Pin (MB991385)
- Tighten the crankshaft pulley centre bolt to the specified torque.
Tightening torque: 167 N·m
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- 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.
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- Insert a wire or pin in the set hole aligned.
NOTE: When replacing the timing belt tensioner adjuster with new parts, the timing belt tensioner adjuster is set with a pin.
- Install the timing belt tensioner adjuster to the engine and then tighten the mounting 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
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Temporarily tighten the timing belt tensioner pulley as shown.
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- Align the timing marks on the camshaft sprocket, crankshaft camshaft drive sprocket and engine oil pump sprocket.
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- Adjust the timing mark of the engine oil pump sprocket. Unplug the cylinder block plug. Insert a bolt (M6, section width 10 mm, nominal length 45 mm) from the plug hole. If the bolt comes in contact with the balancer shaft, turn the engine oil 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.
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- Incorporate the valve timing belt in the following manner so that the tensile force of the belt is not lax.
- Place the valve timing belt on the timing belt tensioner pulley and crankshaft camshaft driver sprocket and then support it with your left hand so it does not slide.
- Place the valve timing belt on the engine oil pump sprocket while pulling it with the right hand.
- Place the valve timing belt on the timing belt idler pulley.
- Place the valve timing belt on the camshaft sprocket.
CAUTION)
- Turn the timing belt tensioner pulley in the direction shown in the figure using special tool tensioner wrench (MD998767) to apply tension to the valve timing belt. Then temporarily tighten and fix the timing belt tensioner pulley mounting bolt.
)
- 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.
- Set special tool adjusting bolt (MD998738) used when removing the valve timing belt.
- Gradually screw in the special tool to a position in which the wire or pin inserted in the timing belt tensioner adjuster lightly moves.
CAUTION- Turn the crankshaft 1/4 of a revolution in the anti-clockwise direction.
- Turn the crankshaft in the clockwise direction, align each timing mark to set No.1 cylinder to TDC of its compression stroke.
- Loosen the timing belt tensioner pulley mounting bolt.
CAUTION)
- With special tool tensioner wrench (MD998767) and torque wrench, apply tension torque 3.5 N·m to the valve timing belt, 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 adjuster.
- Remove special tool adjusting bolt (MD998738), and install the rubber plug to the timing belt under cover.
- Rotate 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 with a light load. When wire or pin can be lightly removed, appropriate tension is applied on timing belt. In this case, remove wire or pin.
)
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Also the projection of timing belt tensioner adjuster rod (A) 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
- Check again that the timing marks on sprockets are aligned.