REMOVAL AND INSTALLATION

Removal steps 1. Timing belt front upper cover 2. Camshaft position sensor 3. Harness bracket 4. Ignition coil bracket 5. Timing belt lower cover >>G<< · Timing belt tension adjustment <<A>> 6. Timing belt >>F<< 7. Timing belt tensioner pulley >>E<< 8. Timing belt tensioner arm >>D<< 9. Timing belt auto-tensioner 10. Timing belt Idler pulley 11. Bracket 12. Crank angle sensor <<B>> >>C<< 13. Crankshaft sprocket >>C<< 14. Crankshaft angle sensing blade >>B<< · Timing belt B tension adjustment >>A<< 15. Timing belt B tensioner <<C>> >>A<< 16. Timing belt B

1. caution Never turn the crankshaft anti-clockwise. Turn the crankshaft in the forward direction (clockwise) to align the timing mark so that No.1 cylinder is at the compression TDC (Top Dead Centre) position.

2.Insert special tool adjusting bolt (MD998738) into the rubber plug hole in the timing belt rear cover.

3. caution The special tool (MD998738) 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 auto-tensioner rod will not easily retract and the special tool may bend. Screw in the special tool (MD998738) until it comes in contact with the timing belt tensioner arm.

4.Gradually screw in the special tool (MD998738). Then align the timing belt auto-tensioner rod set hole A with the timing belt auto-tensioner cylinder set hole B.

5.Insert a wire in the set hole. 6. caution To reuse the timing belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk. After removal of special tool (MD998738), loosen the timing belt tensioner pulley mounting bolt and remove the timing belt.

1.Use the following special tools to support the crankshaft sprocket. Special spanner (MB991367) Pin (MB991385) 2.Loosen the crankshaft sprocket bolt and remove the crankshaft sprocket.

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.

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.

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. 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

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.

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. 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. (4) Press "Hz" button twice to change the display to the frequency display (Hz). (5) 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. 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 note To take the measurement repeatedly, fillip the belt again. (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.

1.Clean or degrease the crankshaft, the crankshaft angle sensing blade, the crankshaft sprocket, crankshaft sprocket washer and crankshaft sprocket bolt as shown. note Also clean the degreased surfaces. 2.Install the crankshaft angle sensing blade and crankshaft sprocket in the direction shown. 3.Place the larger chamfer side of the crankshaft sprocket washer in the direction shown and then assemble on the crankshaft sprocket bolt. 4.Apply some engine oil to the crankshaft sprocket bolt bearing surface and screw.

5.Use the following special tools as during removal to support the crankshaft sprocket. Special spanner (MB991367) Pin (MB991385) 6.Tighten the crankshaft pulley centre bolt to the specified torque. Tightening torque: 167 N·m 7.Loosen the crankshaft pulley centre bolt fully. 8.Tighten the crankshaft pulley centre bolt to the specified torque again. Tightening torque: 167 N·m

1.Install according to the following procedures when the timing belt auto-tensioner rod is fully extended. (1) caution If the compression is too fast, the procedure may damage the rod. Slowly compress the timing belt auto-tensioner rod using a press or vice, then align the set hole A of the rod with set hole B of the timing belt auto-tensioner cylinder. (2) Insert a wire or pin into the aligned set hole. note When replacing the timing belt auto-tensioner with new parts, the timing belt auto-tensioner is set with a pin. 2.Assemble the timing belt auto-tensioner to the engine, then tighten the assembling bolt to the specified torque. Do not remove the wire or pin until the tension of the timing belt is adjusted. Tightening torque: 23 ± 6 N·m

Temporarily tighten the timing belt tensioner pulley as shown.

1.Align the timing marks on the camshaft sprocket, crankshaft sprocket and engine oil pump sprocket.

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 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 timing belt is assembled.

3.Install the timing belt as follows: (1) Place the timing belt on the timing belt tensioner pulley and crankshaft sprocket. Support it with your hand so it does not slide. (2) Place the timing belt on the engine oil pump sprocket while pulling it with your other hand. (3) Place the timing belt on the timing belt idler pulley. (4) caution Incorporate the 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 tight. Place the timing belt on the camshaft sprocket.

4.Turn the timing belt tensioner pulley in the direction shown using special tool tensioner wrench (MD998767) to apply tension to the timing belt. Then pre-tighten the timing belt tensioner pulley. 5.Check that the timing marks are aligned.

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 timing belt tension.

1.Set special tool adjusting bolt (MD998738) when removing the timing belt. 2. 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 auto-tensioner. Gradually screw in special tool (MD998738) until the wire or pin inserted in the timing belt auto-tensioner lightly moves. 3.Turn the crankshaft 1/4 turn anti-clockwise. 4.Turn the crankshaft in the clockwise direction until you align each timing mark to set No.1 cylinder to TDC of its compression stroke. 5.Loosen the timing belt tensioner pulley mounting bolt.

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. 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: 41 ± 10 N·m

7.Remove wire or pin inserted to timing belt auto-tensioner.

8.Remove the special tool adjusting bolt (MD998738), and install the rubber plug to the timing belt rear cover. 9.Rotate the crankshaft clockwise two turns, and leave it for about 15 minutes.

10.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 auto-tensioner rod 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 timing belt tension.

12. caution Always check the tightening torque of the crank shaft bolt when turning the crack shaft bolt anti-clockwise. Re-tighten if it is loose. Check again that the timing marks on sprockets are aligned.