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| caution |
Water or oil on the belt
shortens its life drastically, so
the removed timing belt, sprocket, and tensioner
must be washed or immersed in solvent. Replace
parts if contaminated.
If there is oil or
water on any part, check the front case
oil seals, camshaft oil seal, and water pump for
leaks.
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If the timing belt is to be reused, make an arrow
mark with something like chalk on the
back of the belt indicating the direction of rotation so it
may be reinstalled in the same direction.
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1.Remove the plug on the
left side of cylinder block.
2.Insert a crosspoint
screwdriver (shank diameter: 8 mm) to prevent the
counterbalancer
shaft from rotating.
3.Remove the flange
nut.
4.Remove the oil pump sprocket.
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1.Hold the flywheel with the
special tool Flywheel stopper (MB991883).
2.Remove
the crankshaft bolt.
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Use the special tool Crankshaft
sprocket puller (MD998778) if the sprocket is stuck and
hard to remove.
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| caution |
Water or oil on the belt
shortens its life drastically, so
the removed timing belt, sprocket, and tensioner
must be free from oil and water. These parts
should not be washed or immersed in solvent.
Replace parts if contaminated.
If there
is oil or water on each part, check the front
case oil seals, camshaft oil seal and water pump
for leaks.
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If the timing belt is to be used, make an arrow mark
with something like chalk on the
back of the timing belt indicating the direction of rotation
so it may be reinstalled in the
same direction.
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1.Use the special tool
Sprocket stopper (MD998785) to prevent the counterbalancer
shaft
sprocket from rotating.
2.Remove the
counterbalancer shaft mounting bolt.
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Use the special tool Crankshaft
sprocket puller (MD998778) if the sprocket is stuck and
hard to remove.
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1.Use the special tools to
prevent the camshaft sprocket from
rotating.
- End yoke holder (MB990767)
- Pulley holder pin (MD998719)
2.Remove the camshaft sprocket bolt.
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1.Use the special tools to
prevent the camshaft sprocket from
rotating.
- End yoke holder (MB990767)
- Pulley holder pin (MD998719)
2.Tighten the camshaft sprocket bolt to the
specified torque.
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Wipe the dirt on the crankshaft
sprocket B and the sprocket fitting surface
of the crankshaft. using a rag, and then remove the grease
from the portion shown in the illustration.
| note |
Remove grease to prevent the
coefficient of friction of the pressing portion
from declining
due to adhesion of oil.
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1.Smear slightly oil on the
outer surface of the spacer that comes into contact with the
oil seal.
2.Install the spacer with the chamfered
end toward the oil seal. Reversing the direction
will cause damage to the oil seal lip.
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Use the special tool Sprocket
stopper (MD998785) as shown in the drawing to prevent the
counterbalancer shaft sprocket from rotating, then tighten
the sprocket mounting bolt to the
specified torque.
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1.Ensure that the crankshaft
sprocket B timing marks and balancer shaft sprocket timing
marks are aligned.
2.Install the timing belt B on
the crankshaft sprocket B 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 timing belt B 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.
4.Adjust the timing
belt B tension.
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1.
| 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.
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With your fingers, lift the timing belt B tensioner
in the direction of the arrow. Apply
pressure of 3.0 ±
0.4 N·m to the timing belt B. Tighten the assembling
bolt
to the specified torque. Then, fix the timing belt B
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 the sprocket timing marks are
aligned.
3.Adjust the timing belt B tension in the
following procedure.
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4.<Special tool
(MB992080) is used>
(1)
Connect the special tool microphone assembly (MB992082) to
the special tool belt tension
meter (MB992081) of the special tool belt tension meter set
(MB992080).
(2)
Press the "POWER" button to turn on the power supply.
(3)
Press the numeral key of "1" and check that "No.1" appears
on the upper left of the
display.
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| note |
This operation is
to temporarily set the preset data
such as the belt specifications,
because if the measurement is taken
without input of the belt
specifications, conversion to
tension value (N) cannot be made,
resulting in judgement of
error.
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(4)
Press "Hz" button twice to change the display to the
frequency display (Hz).
(5)
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| caution |
- The temperature of the
surface of the belt should
be as close to normal
temperature as
possible.
- Do not allow any
contaminants such as water
or oil to get onto the
microphone.
- If strong gusts of wind blow
against the microphone or if
there are any loud sources
of noise nearby, the values
measured by the microphone
may not correspond to actual
values.
- If the microphone is
touching the belt while the
measurement is being made,
the
values measured by the
microphone may not
correspond to actual
values.
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Hold the microphone to the middle of the belt
between the pulleys (at the place indicated
by arrow), approximately 10 -
15 mm away from the rear surface of the belt so that
it is perpendicular to the belt (within an angle of ±
15 degree).
(6)
Press the "MEASURE" button.
(7)
Gently tap the middle of the belt between the pulleys (the
place indicated by the
arrow) with your finger as shown in the illustration, and
measure that the vibration frequency of
the belt is within the standard value.
Standard
value: 62 -
98 Hz
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| note |
To take the
measurement repeatedly, fillip the
belt again.
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(8)
After the completion of the measurement, press and hold the
"POWER" button to turn
off the power supply.
5.If not within the standard
value, adjust the belt tension again.
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1.Wipe the dirt on the
washer and on the thread hole of the crankshaft
using a rag.
2.Wipe the dirt on the crankshaft
sprocket, crankshaft sensing blade
and the crankshaft sprocket B using a rag, and then remove
the grease from the portion shown
in the illustration.
| note |
Remove grease to prevent the
coefficient of friction of the pressing portion
from declining
due to adhesion of oil.
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3.Install the crankshaft sensing blade and
crankshaft pulley.
4.Apply an appropriate and
minimum amount of engine oil to the threaded
portion of the crankshaft and lower part of the
flange.
5.With the chamfered side on the inside of
the washer facing the bolt
top, install the washer to the crankshaft pulley
bolt.
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6.Hold the flywheel using
the special tool Flywheel stopper
(MB991883).
7.Tighten the crankshaft pulley centre
bolt to the specified torque.
Tightening
torque: 167 N·m
8.Loosen the
crankshaft pulley centre bolt fully.
9.Tighten the
crankshaft pulley centre bolt to the specified torque
again.
Tightening torque: 167
N·m
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|
1.Prevent the
counterbalancer shaft from rotating in the same method as in
the removal procedure.
2.Install the oil pump
sprocket.
3.Apply a necessary minimum amount of
engine oil to the seating surface of the flange
nut.
4.Tighten the flange nut to the specified
torque.
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Coat the bolt indicated in the
drawing with sealant before it is
installed.
Specified
sealant:
Three bond 2310 or
equivalent
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1.If the auto-tensioner rod
remains in its fully extended position, reset it to the
retracted
position as follows:
(1)
Clamp the auto-tensioner in a vise at right angles to the
jaws.
(2)
Push in the rod little by little with the vise until the set
hole A in the rod is
aligned with the set hole "B" in the cylinder.
(3)
Insert a piece of wire (1.4 mm diameter) into the set
holes.
(4)
Remove the auto-tensioner from the vise.
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2.Install the auto-tensioner
in position. Leave the wire installed until the
auto-tensioner
is completely installed.
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Install the tensioner pulley with
its holes aligned as shown in the drawing.
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1.Check that the tensioner
pulley is installed with its holes correctly aligned. (See
>>K<<
 )
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2.Align the timing mark on
the camshaft sprocket with that on the cylinder
head.
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3.Align the timing mark on
the crankshaft sprocket with that on the front
case.
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4.Align the timing mark on
the oil pump sprocket with that on the front case.
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5.Check that the oil pump
sprocket is in the correct phase as follows: Remove the plug
from
the cylinder block and insert a crosspoint screwdriver with
a shank diameter of 8 mm through
the hole. If it can be inserted 60 mm or more, the sprocket
is in the correct phase. If the
insertion depth is up to 20 -
25 mm, the screwdriver is blocked by the counterbalancer
shaft. Then turn the oil pump sprocket one turn and realign
the timing marks. Then check that
the screwdriver can be inserted 60 mm or more. Keep the
screwdriver inserted until installation
of timing belt is finished.
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|
6.Install the timing belt on
the crankshaft sprocket, idler pulley, camshaft sprocket,
and
tensioner pulley in that order.
7.Lift the
tensioner pulley in the direction of the arrow and tighten
the tensioner
pulley bolt.
8.Check that all the timing marks are
aligned.
9.Rotate the crankshaft counter clockwise
a quarter (1/4) turn.
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|
10.Set the special tool set
screw (MD998738) as shown and screw it in up to the position
where the wire inserted in the auto-tensioner when in
stalling it can be moved lightly.
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|
11.Install the special tool
Tension pulley socket wrench (MD998767) on the tensioner
pulley
and attach a torque wrench to the tool.
12.Apply a
torque of 3.5 N·m to the tensioner pulley using the
torque wrench.
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|
13.While holding the
tensioner pulley to prevent it from rotating, tighten the
centre bolt
to the specified torque.
Tightening torque: 41
±
10 N·m
14.Turn the crankshaft
clockwise two turns, then let it alone for approx. 15
minutes.
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|
15.Check that the wire that
was inserted in the auto-tensioner when it was installed can
be moved freely.
If the wire can be pulled freely, the
belt tensioner is adjusted properly. Remove the
wire. At that time, check that the auto-tensioner rod
extends by the specified amount.
Standard
value: 3.8 -
4.5 mm
16.If the wire cannot be pulled out
freely, perform the steps 10. through 13. again to
make the belt tension proper.
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