Removal and Installation

REMOVAL AND INSTALLATION

NOTE:

*1: In case that the amount of rod protrusion is 5 mm with the set pin inserted.
*2: In case that the amount of rod protrusion is 1 mm with the set pin inserted.

- MB990767: End Yoke Holder
- MD998715: Pins
- MD998767: Tensioner Pulley Wrench
- MD998769: Crankshaft Spacer

REMOVAL SERVICE POINTS

[[A]] TIMING BELT REMOVAL

1.
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. These parts should not be washed or immersed in solvent. Replace parts if contaminated.
If there is oil or water on any part, check the front case oil seal, camshaft oil seal, and water pump for leaks.

Mark the belt running direction for reinstallation.
2. Loosen the tensioner pulley bolt, and then remove the timing belt.

[[B]] CAMSHAFT SPROCKET REMOVAL

1. While holding the camshaft sprocket with special tools MB990767 and MD998715, loosen the camshaft sprocket bolt.
2. Remove the camshaft sprocket.

INSTALLATION SERVICE POINT

]]A[[ CAMSHAFT SPROCKET INSTALLATION

1. Fit the camshaft sprocket to the front end of the camshaft.
2. While holding the camshaft sprocket with special tools MB990767 and MD998715, tighten the camshaft sprocket bolt.
Tightening torque: 88± 10Nm (65± 7 ft-lb)

]]B[[ CRANKSHAFT SENSING BLADE / CRANKSHAFT SPACER / CRANKSHAFT SPROCKET INSTALLATION

1. Clean the hole in the crankshaft sprocket.
2. Clean and degrease the mating surfaces of the crankshaft sprocket, sensing blade, and spacer.
NOTE:
Degreasing is necessary to prevent decrease in friction on the mating surfaces.

3. Align the location of pin and pin hole, and then apply equal force in the direction of the arrow.

CAUTION:
Do not bend the sensing blade when installing sprocket.

4. Install the crankshaft sprocket to the crankshaft.

]]C[[ AUTO-TENSIONER INSTALLATION

[In case that the amount of rod protrusion is 5 mm with the set pin inserted.]

If the auto-tensioner rod is fully extended, reset it as follows.
1. Clamp the auto-tensioner in the vise with soft jaws.
2. Push in the rod little by little with the vise until set hole A in the rod is aligned with hole B in the cylinder.
3. Insert a wire [1.4 mm (0.055 inch) in diameter] into the set holes.
This auto-tensioner setting wire will be used during timing belt alignment.
4. Unclamp the auto-tensioner from the vise.

]]D[[ AUTO-TENSIONER INSTALLATION

[In case that the amount of rod protrusion is 1 mm with the set pin inserted.]

CAUTION:

- If the lateral type press is used, the appropriate air bleeding is not carried out. Always use longitudinal type press.

- To prevent damage to the auto tensioner, do not apply the load of 5,000N (1,124 lb) or more.

- To prevent damage to the auto tensioner, do not press the rod below the cylinder end plane.

1. Set the auto tensioner to the longitudinal type press as shown in the illustration.
2. Push in the rod little by little with the longitudinal type press until set hole A in the rod is aligned with hole B in the cylinder.
3. Insert a wire [2 mm (0.08 inch) in diameter] into the set holes.
This auto-tensioner setting wire will be used during timing belt alignment.

CAUTION:
To prevent the air from being incorporated, keep the auto tensioner with its rod upward after the air bleeding.

]]E[[ TIMING BELT INSTALLATION

[In case that the amount of rod protrusion is 5 mm with the set pin inserted.]

CAUTION:
Do not turn the camshaft when the piston in No.1 cylinder is at top dead center on the compression stroke. Doing so can cause the lifted valve to hit against the piston, damaging parts.

1. Install special tool MD998769 and the crankshaft pulley washer, and then tighten the crankshaft bolt.
2. Align the timing mark on the crankshaft sprocket with the timing mark on the oil pump case, and then rotate the sprocket three teeth counterclockwise.

3. Align the timing mark on the left bank camshaft sprocket with the timing mark on the rocker cover.
4. Align the timing mark on the right bank camshaft sprocket with the timing mark on the rocker cover.
NOTE:
Align the timing mark, on the right bank, with F.

5. Align the timing mark on the crankshaft sprocket with the timing mark on the oil pump case.
6. Install the timing belt on each sprocket and pulley in the following sequence. Do not leave the belt slack between each sprocket and pulley.
(1) Crankshaft sprocket
(2) Idler pulley
(3) Left bank camshaft sprocket
(4) Water pump pulley
(5) Right bank camshaft sprocket
(6) Tensioner pulley

7. Install special tool MD998767 to the tensioner pulley. While pushing the pulley lightly against the belt using the special tool, tighten the flange bolt.
Tightening torque: 48± 6Nm (35± 4 ft-lb)
8.

Check to see that the timing marks of all the sprockets are in alignment.

9. Rotate the crankshaft a quarter turn counterclockwise. Then rotate it back clockwise to verify that all the timing marks are aligned.

10. Loosen the flange bolt securing the tensioner pulley, and then mount special tool MD998767 and a torque wrench on the tensioner pulley.
11. Torque it to 4.4 Nm (39 in-lb) with the torque wrench.
12. While holding the tensioner pulley in position, tighten the flange bolt to the specified torque.
Tightening torque: 48± 6Nm (35± 4 ft-lb)
13. Rotate the crankshaft two turns clockwise and leave it alone for approximately five minutes.

14. Check to see whether the metal wire inserted when the auto-tensioner was installed can be removed without any resistance.
If the metal wire can be removed without any resistance, it means that the belt has a proper tension. Therefore, remove the metal wire. In this condition, check that the rod protrusion of the auto-tensioner is within the standard value.
Standard value: 4.8 - 6.0 mm (0.19 - 0.24 inch)
If the metal wire offers resistance when removed, repeat the previous steps 10 through 13 until proper belt tension is obtained.

]]F[[ TIMING BELT INSTALLATION

[In case that the amount of rod protrusion is 1 mm with the set pin inserted.]

CAUTION:
Do not turn the camshaft when the piston in Number 1 cylinder is at top dead center on the compression stroke. Doing so can cause the lifted valve to hit against the piston, damaging parts.

1. Install special tool MD998769 and the crankshaft pulley washer, and then tighten the crankshaft bolt.
2. Align the timing mark on the crankshaft sprocket with the timing mark on the oil pump case, and then rotate the sprocket three teeth counterclockwise.

7. Lightly pressing the tensioner pulley against the belt, insert the hexagonal wrench having the width of 5mm (0.2 inch) between the tensioner body and tensioner arm to temporarily tighten the center bolt.

8. Inserting the hexagonal wrench, loosen the center bolt of the tensioner pulley to install the special tool the torque wrench. Applying the torque of 4.4 Nm (39 in-lb) to prevent the tensioner pulley from rotating, tighten the center bolt to 48 ± 6 Nm (35 ± 4 ft-lb).
9.

Check to see that the timing marks of all the sprockets are in alignment.

10. Rotate the crankshaft a quarter turn counterclockwise. Then rotate it back clockwise to verify that all the timing marks are aligned.

11. Loosen the flange bolt securing the tensioner pulley, and then mount special tool MD998767 and a torque wrench on the tensioner pulley.
12. Torque it to 4.4 Nm (39 in-lb) with the torque wrench.
13. While holding the tensioner pulley in position, tighten the flange bolt to the specified torque.
Tightening torque: 48± 6Nm (35± 4 ft-lb)

14. Pull out set pin having dia.2 mm (0.08 inch) inserted into the auto tensioner.

CAUTION:
If the hexagonal wrench is removed first, the timing belt would possibly become loose and come off the tooth.

15. Pull out the hexagonal wrench.
16. Rotate the crankshaft two turns clockwise and let it stand for approximately five minutes.

17. Check whether the amount of the rod protrusion of the auto tensioner is within the standard value.
Standard value: 4.8 - 6.0 mm (0.189 - 0.236 inch)
18. When it deviates from the standard value, carry out the tension adjustment of the tensioner pulley again to obtain the appropriate belt tension.

]]G[[ ENGINE SUPPORT BRACKET, RIGHT INSTALLATION

The mounting bolts of the right engine support bracket must be tightened in the order shown in the illustration.
Tightening torque: 45± 5Nm (34± 3 ft-lb)
Bolt length

85 mm (33.5 inch) - Bolt 3
95 mm (37.4 inch) - Bolts 2 and 4
100 mm (39.4 inch) - Bolt 1