TIMING BELT REMOVAL/INSTALLATION [MZ-CD 1.6]

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1.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.6].)

2.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.6].)

3.  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].)

4.  Remove the wiring harness.

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 cover
3
Crankshaft pulley installation bolt
(See Crankshaft Pulley Installation Bolt Removal Note.)
(See Crankshaft Pulley Installation Bolt Installation Note.)
4
Crankshaft pulley
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.  Hold the crankshaft pulley by using the SSTs.

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2.  Remove the crankshaft pulley installation bolt.


No.3 Engine Mount Rubber Removal Note

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

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Timing Belt Tensioner, Timing Belt Removal Note

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

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

Tightening torque
20 N·m {2.0 kgf·m, 15 ft·lbf}

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 the new 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.  Remove or discard the crankshaft pulley installation bolt.


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}


Crankshaft Pulley Installation Bolt Installation Note

1.  Hold the crankshaft pulley by using the SSTs.

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2.  Tighten the crankshaft pulley installation bolt.

1.  Tightening to 35 N·m {3.6 kgf·m, 26 ft·lbf}
2.  Tightening to 190°