REMOVAL AND INSTALLATION







Removal steps


1.
Timing belt front upper cover, right


2.
Timing belt front upper cover, left


3.
Crank angle sensor


4.
O-ring
<<A>>
>>D<<
5.
Auto-tensioner
<<B>>
>>E<<
6.
Timing belt


7.
Tensioner arm
<<C>>
>>C<<
8.
Idler pulley

>>B<<
9.
Crankshaft sprocket


10.
Key
<<D>>
>>A<<
11.
Camshaft sprocket bolt


12.
Camshaft sprocket


13.
Timing belt rear cover

REMOVAL SERVICE POINTS



<<A>> AUTO-TENSIONER REMOVAL



1.Remove the upper mounting bolt of the timing belt auto-tensioner.
2.
caution The auto-tensioner rotates centring on the flange bolt due to the rod thrust, so please make sure your finger is not trapped.
Loosen the lower mounting bolt of the auto-tensioner slowly and slide the auto-tensioner slightly. Remove the rod from the tensioner arm.
3.Remove the lower mounting bolt of the auto-tensioner.

<<B>> TIMING BELT REMOVAL


1.Before the timing belt is removed, align the timing marks of the camshaft sprocket and crankshaft sprocket with the No.1 at the Top Dead centre of the compression stroke.
caution Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must be kept free from oil and water. Do not immerse parts in cleaning solvent.

Mark the belt running direction for reference in reinstallation.
note If there is oil or water on any part, check the front case oil seal, camshaft oil seal, and water pump for leaks.
note After the timing belt is removed, do not turn the crankshaft sprocket and the camshaft sprocket.

<<C>> IDLER PULLEY REMOVAL



caution Because of the shallow hexagon hole of the hexagon socket head bolt, firmly insert the tool and carefully work not to damage the hexagon hole.
Remove the idler pulley using a hexagon wrench with 8 mm width across flats.

<<D>> CAMSHAFT SPROCKET BOLT REMOVAL



Use special tools End yoke holder (MB990767) and Pins (MD998719) to prevent the camshaft sprocket from turning, and then loosen the camshaft sprocket bolt.

INSTALLATION SERVICE POINTS



>>A<< CAMSHAFT SPROCKET BOLT INSTALLATION



Use special tools End yoke holder (MB990767) and Pins (MD998719) to prevent the camshaft sprocket from turning, and then tighten the camshaft sprocket bolt.
Tightening torque: 90 ± 10 N·m

>>B<< CRANKSHAFT SPROCKET INSTALLATION



1.Clean the hole in the crankshaft sprocket.
2.Clean and degrease the mating surfaces of the crankshaft sprocket.
note Degreasing is necessary to prevent decrease in friction on the mating surfaces.
3.Install the crankshaft sprocket to the crankshaft.

>>C<< IDLER PULLEY INSTALLATION



caution Because of the shallow hexagon hole of the hexagon socket head bolt, firmly insert the tool and carefully work not to damage the hexagon hole.
Install the idler pulley using a hexagon wrench with 8 mm width across flats.

>>D<< AUTO-TENSIONER INSTALLATION


caution
Always bleed the auto-tensioner of air before installing the auto-tensioner. (Refer to auto tensioner inspection .)

>>E<< TIMING BELT INSTALLATION


caution Remove and install the timing belt, aligning the timing marks of the crankshaft sprocket and the camshaft sprocket with the No.1 at the Top Dead centre of the compression stroke.


1.Check the timing marks of the crankshaft sprocket and the camshaft sprocket are aligned with the No.1 at the Top Dead centre of the compression stroke. If they are not, align the timing marks again, paying attention to the interference between the valve and the piston.
2.Install the timing belt on each sprocket in the following sequence.
(1) Install the timing belt on the crankshaft sprocket and then on the water pump pulley, while tightening it to prevent slackness.
(2) Line up the timing marks of the left bank camshaft sprockets.
(3) Install the timing belt on the idler pulley, while taking up the slack.
(4) Install the timing belt on the right bank camshaft sprocket.
(5) Install the timing belt on the tensioner pulley.
3.Check to see that the timing marks of all the sprockets are in a alignment.
4.Pull out the pin of the auto-tensioner.
5.Remove the setting pin that has been inserted into the timing belt auto-tensioner.



6.Use special tool crankshaft wrench (MD998716), turn the crankshaft clockwise twice to align the timing marks.

7.Wait for at least five minutes, then check that the timing belt auto-tensioner pushrod extends within the standard value range.
Standard value (A): 9.1 - 13.4 mm
8.If not, repeat the operation in steps 1 to 7 above.
9.Check again that the timing marks of the each sprockets are aligned.





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