REMOVAL AND INSTALLATION

Removal steps · Control wiring harness connection · Battery wiring harness connection · Variable geometry control solenoid valve (Refer to GROUP 11D - Solenoid Valve and Vacuum hose ) <High power engine>. 1. Auto-tensioner 2. Timing belt front upper cover 3. Timing belt front lower cover <<A>> >>D<< 4. Auto-tensioner <<B>> >>D<< 5. Timing belt >>D<< 6. Tensioner arm 7. Idler pulley 8. Idler pulley

Removal steps >>C<< 9. Crankshaft sprocket >>C<< 10. Flange <<C>> >>B<< 11. Timing belt B >>A<< 12. Hexagon socket head bolt >>A<< 13. Tensioner spacer B >>A<< 14. Tensioner spring B >>A<< 15. Timing belt tensioner B

1. 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.

2. caution To reuse the timing belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk, etc. Remove the timing belt.

1. caution To reuse the timing belt B, draw an arrow indicating the rotating direction on the back of the belt using chalk, etc. Loosen the timing belt tensioner B mounting bolts. 2.Push the timing belt tensioner B to water pump side and tighten the timing belt tensioner B mounting bolts. 3.Remove the timing belt B.

1.Install the timing belt tensioner B, tensioner spring B and tensioner spacer B. note Be sure to install the tensioner spring B with its shorter end toward the water pump. 2.Move timing belt tensioner B toward water pump and tighten mounting bolts.

1.Align timing marks on the crankshaft sprocket B, and balancer shaft sprockets with their timing marks. 2.Install balancer timing belt B onto sprockets and ensure that its tension side is not slack.

3.Loosen timing belt tensioner B mounting flange bolt, one to two turns. 4.Tighten the timing belt tensioner B mounting hexagon socket head bolt. 5.timing belt tensioner B mounting flange bolt. note If the bolt is tightened first, the timing belt tensioner B should be turned together, resulting in reduced timing belt tensioner B.

6.Ensure that the deflection is as specified when the timing belt B is pushed by the index finger at the position indicated by an arrow. Belt deflection: 4 - 5 mm

1.Clean and then degrease the crankshaft, the flange and crankshaft sprocket as shown. note Degreasing is necessary to prevent decrease in the friction between contacting surfaces.

2.Assemble the flange by aligning the timing marks of the front lower case and the timing mark of the flange.

1.To reuse the auto-tensioner, bleed the air according to the procedure below, and then set the rod to the auto-tensioner. (1) caution If a horizontal press such as a vice is used, the air entrainment may occur. Thus, a vertical press must be used. If the compression is too fast, the procedure may damage the rod. Make sure to compress slowly and thoroughly. To prevent damage to the auto-tensioner, do not apply the load of 5,000 N or more. To prevent a damage to the auto tensioner, do not push down the rod exceeding the bottom end (a position where the rod protrusion is at 0.5 mm from the auto tensioner). Set the auto-tensioner to the vertical press, and then slowly compress the rod to the bottom end (a position where the rod protrusion is at 0.5 mm from the auto-tensioner). Perform this operation 2 to 3 times. (2) With the rod protruding (a position where the rod protrusion is at 5 mm from the auto-tensioner), check that there is a rigidity when the rod is pushed with a load (100 to 200 N). (3) If the rod rigidity is not obtained by repeating the operations of (1) and (2), replace the auto-tensioner. (4) Compress the rod slowly, and then align the set hole A of the rod with the set hole B of the auto-tensioner body. (5) Insert a wire or pin (2 mm in diameter) in the aligned set hole. note When the auto-tensioner is replaced with a new part, the auto-tensioner is set with a pin. 2.Install the auto-tensioner in position. Leave the wire or pin installed until the auto-tensioner is completely installed. 3.Install the tensioner arm.

4.Align the timing marks of each sprocket.

5.In the order below, install the timing belt without slack. note When installing the timing belt into the crankshaft sprocket, slide the crankshaft sprocket to near the tip of the key, and then install the timing belt. (When installing the timing belt, be careful not to damage the belt by the cut-out of crankshaft sprocket.) After that, install the crankshaft sprocket to the correct position. (1) Crankshaft sprocket (2) Idler pulley (3) Pump sprocket (4) Idler pulley (5) Camshaft sprocket (6) Tensioner pulley 6.Check that the timing marks on sprockets are at the correct positions. 7.Remove the wire or pin of the auto-tensioner. 8.Turn the crankshaft 2 turns clockwise, and then measure the protrusion of auto-tensioner rod. Standard value: 2.3 - 7.6 mm 9.Check again that the timing marks on sprockets are at the correct positions.