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Keep the auto-tensioner
longitudinal. If it were kept lateral, it would possibly
cause
aeration.
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1.Using chalk, etc., mark an
arrow on the back of the timing belt to indicate the
direction
of rotation. This is to ensure correct installation of the
belt in case it is reused.
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1.Use special tool Injection
pump sprocket holder (MB992048), hold the pump
sprocket.
2.
| caution |
Never strike the shaft or
sprocket to remove the sprocket. This
may cause malfunction in the injection pump. Be
sure to use a puller to remove the
sprocket.
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Remove the pump sprocket nut.
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3.Use the special tool
remove the pump sprocket.
- Injection pump sprocket puller (MB992098)
- Crank pulley puller (MB992099)
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Use special tool crankshaft
sprocket puller (MD998778), if the sprocket is stuck and
hard
to remove.
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Using chalk, etc., mark an arrow on
the back of the timing belt to indicate the direction
of rotation. This is to ensure correct installation of the
belt in case it is reused.
| note |
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.
Do not immerse parts in cleaning
solvent.
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| note |
If there is oil or water on
any part, check front case oil seals, camshaft
oil seal and
water pump for leaks.
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1.Remove the plug at the
right side of the cylinder block.
2.Insert a
phillips screwdriver [shank diameter 8 mm]
through the
plug hole and lock the balancer shaft.
3.Loosen
the balancer shaft sprocket nut.
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1.Insert a wrench extension
bar or similar rod and lock the balancer
shaft.
2.Loosen the balancer shaft sprocket
bolt.
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Use special tool crankshaft
sprocket puller (MD998778), if the sprocket is stuck and
hard
to remove.
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1.Clean and then degrease
the front lower case, the crankshaft and the crankshaft
sprocket
"B" as shown.
| note |
Degreasing is necessary to
prevent decrease in the friction between
contacting surfaces.
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2.Install the crankshaft sprocket "B" in the
direction shown in the illustration.
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Install the spacer with its
chamfered end toward the oil seal.
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1.Lock the balancer shaft in
the same way as used in the removal
procedure.
2.Install the balancer shaft sprocket
and tighten the bolt to the specified torque of
36 ± 3 N·m.
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1.Lock the balancer shaft in
the same way as used in the removal
procedure.
2.Install the balancer shaft sprocket
and tighten the nut to the specified torque of
36 ± 3 N·m.
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1.Install the tensioner,
tensioner spring and spacer.
| note |
Be sure to install the
tensioner spring with its shorter end toward the
water pump.
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2.Move tensioner "B" toward water pump and
tighten mounting bolt.
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1.Align timing marks on the
crankshaft sprocket "B", and silent shaft sprockets with
their
timing marks.
2.Install timing belt "B" onto
sprockets and ensure that its tension side is not
slack.
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3.Loosen tensioner "B"
mounting flange bolt, one to two turns.
4.Tighten
the tensioner "B" attaching hexagon socket head
bolt.
5.Tighten the tensioner "B" attaching flange
bolt.
| note |
If the bolt is tightened
first, the tensioner "B" should be turned
together, resulting
in reduced timing belt "B" tension.
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6.Ensure that the deflection
is as specified when the belt is pushed by the index finger
at the position indicated by an arrow.
Belt
deflection: 4 - 5 mm
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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.
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2.Assemble the flange by
aligning the timing marks of the front lower case and the
timing
mark of the flange.
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1.Use special tool Injection
pump sprocket holder (MB992048) to prevent the pump sprocket
from rotating.
2.Tighten the pump sprocket nut to
the specified torque of 64 ± 5 N·m.
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1.
| caution |
Always bleed the
auto-tensioner of air before installing
the auto-tensioner (Refer to  ).
|
Install the auto-tensioner in position. Leave the
wire or pin installed until the auto-tensioner
is completely installed.
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2.Install the tensioner
arm.
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3.Align the timing marks of
each sprocket.
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4.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
5.Check that the timing marks on
sprockets are at the correct positions.
6.Remove
the wire or pin of the auto-tensioner.
7.Turn the
crankshaft 2 turns clockwise, and then measure the
protrusion of auto-tensioner
rod.
Standard value: 2.3 - 7.6
mm
8.Check again that the timing marks on
sprockets are at the correct positions.
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1.
| caution |
Check that the glow plugs,
glow plug mounting threads and
plug seating surfaces of cylinder head are
dry.
|
When installing the glow plug, screw in one thread
or more with fingers and then tighten
with a tool.
|
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2.Tighten the glow plugs to
9.0 ± 1.0 N·m.
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|
3.Using special tool angle
gauge (MB991614), tighten the glow plug to a further
30° to
40°.
4.Install a glow plug plate to the glow
plug, and then tighten them to the specified
torque of 1.8 ± 0.2 N·m.
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|
1.Clean both mating surfaces
of cover and cylinder block.
2.Apply a 2.3 ±
1 mm wide bead of sealant to the cylinder
block.
Specified sealant: ThreeBond 1207F or
equivalent
| note |
Install the cover immediately
applying sealant.
|
3.
| caution |
After the installation, until
a sufficient period of
time (one hour or more) elapses, do not apply
the oil or water to the sealant application area
or start the engine.
|
Install the cover.
|
|
4.Coat the bolt with
sealant, then install and tighten it.
Specified
sealant: ThreeBond 2310 or equivalent
|
