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With the hose installed, remove the
brake fluid reservoir assembly from the vehicle. (Refer
to GROUP 35A, Master cylinder assembly and brake booster  ).
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1.
| caution |
Never turn the crankshaft
anti-clockwise.
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Turn the crankshaft clockwise, align each timing
mark to set No.1 cylinder to TDC of its
compression stroke.
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2.Remove the timing belt
under cover rubber plug and then set special tool adjusting
bolt
(MD998738).
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3.Screw in the special tool
with hands until it contacts the timing belt tensioner
arm.
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4.
| 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.
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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.
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5.Insert a wire or pin in
the set hole aligned.
6.
| caution |
To reuse the valve timing
belt, draw an arrow indicating the rotating
direction (clockwise) on the back of the belt
using chalk, etc.
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After removal of the special tool, loosen the timing
belt tensioner pulley mounting bolts
and remove the valve timing belt.
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1.Use the following special
tools to hold the crankshaft camshaft drive
sprocket.
- Special spanner (MB991367)
- Pin (MB991385)
2.Loosen the crankshaft pulley centre bolt and
remove the crankshaft pulley washer and
crankshaft camshaft drive sprocket.
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1.Ensure that the crankshaft
balancer shaft drive sprocket timing marks and balancer
shaft
sprocket timing marks are aligned.
2.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.
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3.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.
4.Adjust the
balancer timing belt tension.
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1.
| caution |
When tightening the mounting
bolts, ensure that the tensioner does not
rotate with the bolts. Allowing it to rotate
with the bolts can cause excessive tension of
the belt.
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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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2.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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3.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.
Standard
value:
<When adjusting>
5 -
7
mm
<When replacing>
5 -
7 mm
4.If not within the standard
value, adjust the belt tension again.
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1.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.
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2.Install the crankshaft angle sensing blade
and crankshaft camshaft drive sprocket
in the direction shown.
3.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.
4.Apply a small of engine oil to the
crankshaft pulley centre bolt bearing surface and
screw.
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5.Use the following special
tool as during removal to hold the crankshaft camshaft drive
sprocket.
- Special spanner (MB991367)
- Pin (MB991385)
6.Tighten the crankshaft pulley centre bolt to
the specified torque.
Tightening torque: 167
N·m
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1.Set according to the
following procedures when the timing belt tensioner adjuster
rod is fully extended.
(1)
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| caution |
If the compression
is too fast the procedure may damage
the rod. Make
a point to slowly and thoroughly
compress.
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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.
(2)
Insert a wire or pin in the set hole aligned.
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| note |
When replacing the
timing belt tensioner adjuster with
new parts, the timing belt tensioner
adjuster is set with a pin.
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2.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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1.Align the timing marks on
the camshaft sprocket, crankshaft camshaft drive sprocket
and
engine oil pump sprocket.
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2.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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3.Incorporate the valve
timing belt in the following manner so that the tensile
force of
the belt is not lax.
(1)
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.
(2)
Place the valve timing belt on the engine oil pump sprocket
while pulling it with
the right hand.
(3)
Place the valve timing belt on the timing belt idler
pulley.
(4)
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| caution |
Incorporate the
valve timing belt. Then apply
reverse rotation (anti-clockwise
rotation) pressure to the camshaft
sprocket. Re-check to see that each
timing mark is aligned while
the tension side of the belt is
right.
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Place the valve timing belt on the camshaft
sprocket.
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4.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.
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5.Check that the timing
marks are aligned.
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6. Remove the bolt inserted
in Step 2 above, then assemble the cylinder block
plug.
7.Tighten the cylinder block plug to the
specified torque.
Tightening torque: 30 ±
3 N·m
8.Adjust the valve timing belt
tension.
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1.Set special tool adjusting
bolt (MD998738) used when removing the valve timing
belt.
2.
| caution |
Always screw in the special
tool in with your hands, since use of a spanner
or other tools may damage the wire or pin
inserted in the timing belt tensioner adjuster.
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Gradually screw in the special tool to a position in
which the wire or pin inserted in
the timing belt tensioner adjuster lightly moves.
3.Turn the crankshaft 1/4 of a revolution
in the anti-clockwise direction.
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4.Turn the crankshaft in the
clockwise direction, align each timing mark to set No.1
cylinder
to TDC of its compression stroke.
5.Loosen the
timing belt tensioner pulley mounting bolt.
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6.
| 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.
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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
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7.Remove wire or pin
inserted to timing belt tensioner adjuster.
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8.Remove special tool
adjusting bolt (MD998738), and install the rubber plug to
the timing
belt under cover.
9.Rotate crankshaft clockwise
two turns, and leave it for about 15 minutes.
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10.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.
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
11.If wire or pin cannot be easily
pulled out, repeat Step 1 through Step 9 to reach
proper valve timing belt tension.
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12.
| caution |
Always check the tightening
torque of the crankshaft pulley centre bolt
when turning the crankshaft pulley centre bolt
anti-clockwise. Re-tighten if it is
loose.
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Check again that the timing marks on sprockets are
aligned.
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