TIMING BELT REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6) (EURO4 emission level)]

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1.  Remove the battery cover.

2.  Disconnect the negative battery cable.

3.  Remove the following parts:

(1)  Engine cover
(2)  Drive belt (See DRIVE BELT REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6) (EURO4 emission level)].)
(3)  Coolant reserve tank with the hoses and pipes still connected (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

4.  Position the fuel main and return hoses out of the way.

5.  Remove the wiring harness.

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 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, harness bracket
7
No.3 engine mount bracket
8
Timing belt guide
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.


No.3 Engine Mount Rubber Removal Note

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

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No.3 Engine Mount Rubber Installation Note

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

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Tightening torque
7—13 N·m {72—132 kgf·cm, 62—115 in·lbf}

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

3.  Tighten the installation bolts in the order shown in the figure.

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Tightening torque
1 (nuts): 75—104 N·m {7.7—10 kgf·m, 56—76 ft·lbf}
2 (bolts): 71—93 N·m {7.3—9.4 kgf·m, 53—68 ft·lbf}


Timing Belt Pulley, Timing Belt Removal Note

1.  Align the camshaft pulley using the SST.

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2.  Loosen the timing belt tensioner installation bolt.

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3.  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 fuel pump pulley using the SST.

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2.  Remove the SST the fuel pump pulley.

3.  Install the timing belt pulley.

Note
•  Install the old crankshaft pulley bolt. Do not tighten the crankshaft pulley bolt at this stage.

4.  Install the crankshaft pulley installation bolt

5.  Align the crankshaft pulley using the SST.

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6.  Align the camshaft pulley using the SST.

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7.  Remove the SST from the camshaft pulley.

8.  Install the new timing belt.

9.  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.

10.  Remove the SST.

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11.  Rotate the crankshaft 10 revolutions.

Caution
•  Only rotate the crankshaft in the normal direction of rotation.

12.  Install the SST.

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

13.  Remove the SST.

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14.  Install the SST.

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

15.  Remove the SST.

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16.  Install the SST.

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

17.  Remove the SST.

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18.  Remove the crankshaft pulley retaining bolt, and discard the bolt.


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

1.  Tightening to 30 N·m {31 kgf·m, 22 ft·lbf}
2.  Tightening to 180°