TIMING BELT REMOVAL/INSTALLATION [MZ-CD 1.6]

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1.  Disconnect the negative battery cable.

2.  Remove the following parts:

(1)  Engine cover (See ENGINE COVER REMOVAL/INSTALLATION [MZ-CD 1.6].)

(2)  Drive belt (See DRIVE BELT REMOVAL/INSTALLATION [MZ-CD 1.6].)

(3)  Coolant reserve tank with the hoses and pipes still connected (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZ-CD 1.6].)

3.  Set the cooler hose (LO) out of the way. (See REFRIGERANT LINE REMOVAL/INSTALLATION [MZ-CD 1.6].)

4.  Remove the wiring harness.

5.  Remove the water pipe bracket installation bolt and set the water pipe bracket out of the way.

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6.  Remove in the order indicated in the table.

7.  Install in the reverse order of removal.

8.  Start the engine.

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

Crankshaft pulley Removal Note

Caution

•  Take extra care when handling the crankshaft position (CKP) sensor ring.

No.3 Engine Mount Rubber Removal Note

Caution

•  Do not loosen the bolt shown in the figure because it cannot be installed properly if 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 Tensioner, Timing Belt Removal Note

1.  Tighten the crankshaft pulley installation bolt to secure the timing belt pulley.

2.  Align the timing belt pulley using the SST.

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Caution

•  Only rotate the camshaft clockwise.

3.  Align the camshaft pulley using the SST.

Note

•  The SST can only be installed if the valve timing is correct.

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4.  Remove the timing belt tensioner.

5.  Remove the timing belt.

Timing Belt Tensioner, Timing Belt Installation Note

1.  Align a timing belt tensioner with the installation position and temporarily tighten the timing belt tensioner installation bolt by hand.

2.  Install the new timing belt.

3.  Tension the timing belt using the following steps.

Note

•  Using an 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}

4.  Remove the SST.

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5.  Remove the SST.

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Caution

•  Only rotate the crankshaft clockwise.

6.  Rotate the crankshaft 10 revolutions.

Caution

•  Only rotate the camshaft clockwise.

7.  Install the SST.

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

Caution

•  Only rotate the camshaft clockwise.

8.  Install the SST.

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

9.  Insert the pin (commercially-available: 6 mm diameter) into the hole shown in the figure.

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10.  Remove the SST.

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11.  Remove the SST.

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12.  Remove the pin (commercially-available: 6 mm diameter) shown in the figure.

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13.  Discard the crankshaft 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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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 crankshaft pulley installation bolt using the SST (49 D032 316) in two steps.