CAUTION: Do not remove the tape securing the crank shaft position sensor connector and control wiring harness, since the control wire ring harness may contact the power steering oil pump pulley.
[[B]] VALVE TIMING BELT REMOVAL
CAUTION: Never turn the crankshaft anticlockwise.
Turn the crankshaft clockwise, align each timing mark to set No. 1 cylinder to TDC of its compression stroke.
Remove the timing belt under cover rubber plug and then set the special tool MD998738.
Screw in the special tool MD998738 until it comes in contact with the timing belt tensioner arm.
CAUTION: The adjusting bolt 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 tensioner adjuster rod will not easily retract and the adjusting bolt special tool (MD998738) may bend.
Gradually screw in the adjusting bolt special tool (MD998738). Then align the timing belt tensioner adjuster rod set hole A with the timing belt tensioner adjustor cylinder set hole B.
Insert a wire, etc. In the set hole.
CAUTION: To reuse the valve timing belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk.
After removal of adjusting bolt special tool MD998738, loosen the timing belt tensioner pulley mounting bolt and remove the valve timing belt.
[[C]] POWER STEERING OIL PUMP ASSEMBLY REMOVAL
With the hose installed, remove the power steering oil pump assembly from the bracket.
NOTE: Secure the removed power steering oil pump assembly with cord or rope at a position where they will not interfere with the removal of the balancer timing belt.
[[D]] CRANKSHAFT CAMSHAFT DRIVE SPROCKET REMOVAL
Hold the crankshaft camshaft drive sprocket with special tools MB991367 and MD991385.
Loosen the crankshaft pulley center bolt and remove the crankshaft camshaft drive sprocket.
[[E]] BALANCER TIMING BELT REMOVAL
CAUTION: To reuse the balancer timing belt, draw an arrow indicating the rotating direction on the back of the belt using chalk.
INSTALLATION SERVICE POINTS
[[A]] BALANCER TIMING BELT/BALANCER TIMING BELT TENSIONER INSTALLATION
Ensure that the crankshaft balancer shaft drive sprocket timing marks and balancer shaft sprocket timing marks are aligned.
Install the balancer timing belt on the crankshaft balancer shaft drive sprocket and balancer shaft sprocket. There should be no slack on the tension side.
Assemble and temporarily fix the center of the pulley of the balancer timing belt tensioner so that it is at the top left from the center of the assembling bolt, and the pulley flange is at the front-side of the engine.
Adjust the balancer timing belt tension.
]]B[[ BALANCER TIMING BELT TENSION ADJUSTMENT
When measuring the belt deflection:
CAUTION: When tightening the mounting bolts, ensure that the tensioner does not rotate with the bolts. Allowing it to rotate with the bolts can cause excessive tension of the belt.
With your fingers, lift the balancer timing belt tensioner in the direction of the arrow. Apply pressure of [3.0 ±0.4 Nm (26 ±4 inch lbs.) ] To the balancer timing belt. Tighten the assembling bolt to the standard torque. Then, fix the balancer timing belt tensioner.
Tightening torque: 19 ±3 Nm (14 ±2 ft. Lbs.)
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.
Apply a pressure of approximately 100 N (22 pounds) at the center (arrow area) between the sprocket as shown, then inspect whether the belt deflection is within the standard value. Standard value:
At adjustment: 5 - 7 mm (0.20 - 0.27 inch)
At replacement: 5 - 7 mm (0.20 - 0.27 inch)
If not within the standard value, adjust the belt tension again.
When using scan tool MB991502:
CAUTION: When tightening the mounting bolts, ensure that the tensioner does not rotate with the bolts. Allowing it to rotate with the bolts can cause excessive tension of the belt.
Lift with your fingers the balancer timing belt tensioner in the direction of the arrow. Apply a tensile torque of [3.0 ±0.4 Nm (26 ±4 inch lbs.)] To the balancer timing belt so the belt is tense without any looseness. Tighten the assembling bolt to the standard torque in this state. Then, fix the balancer timing belt tensioner. Tightening torque: 19 ±3 Nm (14 ±2 ft. Lbs.)
Connect special tool MB991668 to scan tool MB991502.
Connect special tool MB991704 to scan tool MB991502.
Connect special tool MB991704 to battery.
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.
Select "BELT TENSION" on the menu screen of scan tool MB991502.
Hold special tool MB991668 to the middle of the drive belt between the sprockets (at the place indicated by arrow), approximately 10 - 20 mm (0.40 - 0.78 inch) away from the rear surface of the belt so that it is perpendicular to the belt (within an angle of ±15 degree ).
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.
Gently tap the middle of the belt between the sprockets (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:
At adjustment:76 - 92 Hz
At replacement:76 - 92 Hz
If not within the standard value, adjust the belt tension again.
]]C[[ CRANKSHAFT ANGLE SENSING BLADE/CRANKSHAFT CAMSHAFT DRIVE SPROCKET INSTALLATION
Degrease and clean the crankshaft angle sensing blade and crankshaft camshaft drive sprocket.
Degrease and clean the crankshaft camshaft drive sprocket installation side of the crankshaft.
Install the crankshaft angle sensing blade and crankshaft camshaft drive sprocket in the direction shown.
Clean the screw hole of the crank shaft.
Place the larger chamfer side of the crank shaft pulley washer in the direction shown and then assemble on the crankshaft pulley center bolt.
Apply some engine oil to the crankshaft pulley center bolt bearing surface and screw.
Hold the crankshaft camshaft drive sprocket with special tools MB991367 and MD991385 in the same manner as removal.
Tighten the crankshaft pulley center bolts to the specified torque. Tightening torque: 162 ±5 Nm (120 ±3 ft. Lbs.)
]]D[[ TIMING BELT TENSIONER ADJUSTER INSTALLATION
Install according to the following procedures when the timing belt tensioner adjuster rod is fully extended.
CAUTION: If the compression is too fast, the procedure may damage the rod.
Slowly compress the timing belt tensioner adjuster rod using a press or vice, then align the set hole A of the rod with set hole B of the timing belt tensioner adjuster cylinder.
Insert a wire. Into the aligned set hole.
NOTE: When replacing the timing belt tensioner adjuster with new parts, the timing belt tensioner adjuster is set with a pin.
Assemble the timing belt tensioner adjuster to the engine, then tighten the assembling bolt to the standard torque. Do not remove the wire or pin until the tension of the valve timing belt is adjusted. Tightening torque: 23 ±3 Nm (17 ±2 ft. Lbs.)
]]E[[ TIMING BELT TENSIONER PULLEY INSTALLATION
Temporarily tighten the timing belt tensioner pulley as shown.
]]F[[ VALVE TIMING BELT INSTALLATION
Align the timing marks on the camshaft sprocket, crankshaft camshaft drive sprocket and engine oil pump sprocket.
Adjust the timing mark of the engine oil pump sprocket. Unplug the cylinder block plug. Insert a bolt (M6 x 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 valve timing belt is assembled.
Install the valve timing belt as follows:
Place the valve timing belt on the timing belt tensioner pulley and crankshaft cam shaft driver sprocket. Support it with your hand so it does not slide.
Place the valve timing belt on the engine oil pump sprocket while pulling it with your other hand.
Place the valve timing belt on the timing belt idler pulley.
CAUTION: Install the valve timing belt. Then apply reverse rotation (counterclockwise rotation) pressure to the cam shaft sprocket. Re-check to see that each timing mark is in the proper location while the belt is right.
Place the valve timing belt on the camshaft sprocket.
Turn the timing belt tensioner in the direction shown using special tool MD998767 to apply tension to the valve timing belt. Then pre-tighten the timing belt tensioner pulley.
Check that the timing marks are aligned.
Remove the bolt inserted in Step 2 above, then assemble the cylinder block plug.
Tighten the cylinder block plug to the specified torque. Tightening torque: 30 ±3 Nm (23 ±2 ft. Lbs.)
Adjust the valve timing belt tension.
]]G[[ VALVE TIMING BELT TENSION ADJUSTMENT
Set special tool MD998738 when removing the valve timing belt.
CAUTION: Always screw in special tool MD998738 by hand, since use of a spanner or other tools may damage the wire or pin inserted in the timing belt tensioner adjuster.
Gradually screw in special tool MD998738 until the wire or pin inserted in the timing belt tensioner adjuster lightly moves.
Turn the crankshaft 1/4 turn counterclockwise.
Turn the crankshaft in the clockwise direction until you align each timing mark to set No.1 cylinder to TDC of its compression stroke.
Loosen the timing belt tensioner pulley mounting bolt.
CAUTION: When tightening the mounting bolts, ensure that the timing belt tensioner pulley does not rotate with the bolts. Allowing it to rotate with the bolts can cause deficient tension of the belt.
With special tool MD998767 and torque wrench, apply tension torque [3.5 Nm (31 inch lbs.)], And tighten the timing belt tensioner pulley mounting bolt to the specified torque. Tightening torque: 48 ±5 Nm (36 ±3 ft. Lbs.)
Remove wire or pin inserted to timing belt tensioner.
Remove the adjusting bolt special tool (MD998738), and install the rubber plug to the timing belt under cover.
Rotate the crankshaft clockwise two turns, and leave it for about 15 minutes.
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 tensioner adjuster rod is within the standard value, appropriate tension is applied. Standard value (A): 3.8 - 4.5 mm (0.15 - 0.17 inch)
If wire or pin cannot be easily pulled out, repeat Step 1 through Step 9 to reach proper valve timing belt tension.
CAUTION: Always check the tightening torque of the crank shaft pulley center bolt when turning the crack shaft pulley center bolt counterclockwise. Re-tighten if it is loose.
Check again that the timing marks on sprockets are aligned.
]]H[[ END CAP INSTALLATION
CAUTION: Always replace the end cap with new parts during timing belt servicing.
INSPECTION
TIMING BELT TENSIONER ADJUSTER CHECK
Check for oil leak from seal, and replace it if leak is detected.
Check for wear or damage at the top of the rod. Replace it, if required.
Hold the timing belt tensioner adjuster by hand, and press the top end of the rod onto the metal (e.G. Cylinder block) under a pressure of 98 - 196 N (22 - 44 pounds) to measure the movement of the rod. Standard value: Within 1 mm (0.039 inch)
A: Length when it is free (not pressed)
B: Length when it is pressed
A - B: Movement
If the measured value is out of the standard value, replace the timing belt tensioner adjuster.
BALANCER TIMING BELT TENSION CHECK
Check the balancer timing belt tension as follows:
When measuring the belt deflection
Apply a pressure ofapproximately 100 N (22 pounds) at the center (arrow area) between the sprocket as shown then inspect whether the deflection is within the standard value. Standard value: 5 - 10 mm (0.20 - 0.39 inch)
If not within the standard value, adjust the belt tension.
When using scan tool MB991502
Gently tap the middle of the belt between the sprockets (the place indicated by the arrow) with your finger as shown in the illustration, and check that the vibration frequency of the belt is within the standard value. Standard value:52 - 92 Hz
If not within the standard value, adjust the belt tension.
Not an easy job for at home
Roy
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Monday, October 8th, 2012 AT 4:31 PM
