TIMING BELT REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo]

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1.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo].)

2.  Remove the following parts:

(1)  Engine cover

(2)  Splash shield (RH)

(3)  Drive belt (See DRIVE BELT REPLACEMENT [MZ-CD 1.4 DI Turbo].)

(4)  Remove the coolant reserve tank with the hoses and pipes still connected (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo].)

3.  Remove the wiring harness and wiring harness bracket from the upper timing belt cover.

4.  Set the cooler hose out of the way (With A/C). (See REFRIGERANT LINE REMOVAL/INSTALLATION.)

5.  Remove in the order indicated in the table.

6.  Install in the reverse order of removal.

7.  Start the engine.

8.  Inspect the pulley and belt for runout and contact and adjust them if necessary.

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1	Upper timing belt cover
2	Crankshaft pulley installation bolt (See Crankshaft Pulley Installation Bolt Removal Note.) (See Crankshaft Pulley Installation Bolt Installation Note.)
3	Crankshaft pulley
4	Lower timing belt cover
5	No.3 engine mount rubber (See No.3 Engine Mount Rubber Removal Note.) (See No.3 Engine Mount Rubber Installation Note.)
6	Drive belt auto tensioner
7	No.3 engine mount bracket
8	Timing belt guide (See Timing Belt Pulley, Timing Belt Removal Note.) (See Timing Belt Pulley, Timing Belt Installation Note.)
9	Timing belt pulley (See Timing Belt Pulley, Timing Belt Removal Note.) (See Timing Belt Pulley, Timing Belt Installation Note.)
10	Timing belt (See Timing Belt Pulley, Timing Belt Removal Note.) (See Timing Belt Pulley, Timing Belt Installation Note.)

Crankshaft Pulley Installation Bolt Removal Note

1.  Lock the flywheel using the SST.

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•  Rotate the crankshaft until the SST is aligned with one of the slots in the flywheel.

2.  Remove the SST.

No.3 Engine Mount Rubber Removal Note

Caution

•  Do not loosen the bolt shown in the figure because it cannot be installed properly once it is loosened once.

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1.  Secure the engine and the transaxle using an engine jack.

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Timing Belt Pulley, Timing Belt Removal Note

1.  Rotate the crankshaft clockwise so that the No.1 cylinder is at TDC of the compression stroke.

2.  Align the camshaft pulley using the SST.

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3.  Remove the timing belt guide.

4.  Loosen the timing belt tensioner installation bolt.

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5.  Remove the timing belt pulley.

Caution

•  Do not touch the outer sensor ring.

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Timing Belt Pulley, Timing Belt Installation Note

1.  Align the supply pump pulley using the SST.

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2.  Remove the SST from the supply pump pulley.

3.  Align the camshaft pulley using the SST.

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4.  Remove the SST from the camshaft pulley.

5.  Install the timing belt pulley.

6.  Install the old crankshaft pulley installation bolt.

7.  Align the crankshaft using the SST.

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8.  Install the timing belt.

9.  Tension the timing belt using the following steps.

Note

•  Using a hexagonal wrench, maintain tension until the timing belt tensioner bolt is tightened.

(1)  Turn the timing belt tensioner adjustment arm counterclockwise to apply slight tension to the timing belt.

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(2)  The pointer must be positioned between the sides of the window.

(3)  Tighten the timing belt tensioner installation bolt.

Tightening torque

30 N·m {3.1 kgf·m, 22 ft·lbf}

10.  Remove the SST from the timing belt pulley.

11.  Install the timing belt guide.

12.  Rotate the crankshaft 10 revolutions.

13.  Install the SSTs to each pulley in the positions shown in the figures and verify that timing can be performed.

•  If the SST cannot be installed, repeat the previous steps.

Timing belt pulley

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Camshaft pulley

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Supply pump pulley

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14.  Remove the old crank shaft pulley installation bolt.

No.3 Engine Mount Rubber Installation Note

1.  Tighten the No. 3 engine mount bracket stud bolts.

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2.  Secure the engine and the transaxle using an engine jack.

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3.  Install the No.3 engine mount, and then temporarily tighten the installation bolts and nuts.

4.  Tighten the installation nuts and bolts by order of A, B.

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5.  Remove the engine jack.

Crankshaft Pulley Installation Bolt Installation Note

1.  Lock the flywheel using the SST.

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•  Rotate the crankshaft until the special tool aligns with one of the slots in the flywheel.

2.   Tighten the new crankshaft pulley installation bolt in two steps.