Removal and Installation

REMOVAL AND INSTALLATION









Required Special Tools:

- MB990767: End Yoke Holder

- MD998716: Crankshaft Wrench

- MD998719: Pins

REMOVAL SERVICE POINTS

[[A]] AUTO-TENSIONER REMOVAL





1. Remove the upper tightening bolt of the auto-tensioner.
2.
CAUTION:
The auto-tensioner rotates centering on the flange bolt due to the rod thrust, so please make sure your finger is not trapped.

Slowly loosen the (lower) tightening bolts of the auto-tensioner. Remove the auto-tensioner rod from the tensioner arm and tilt the auto-tensioner to the stopper position.
3. Remove the lower tightening bolt of the auto-tensioner.

[[B]] TIMING BELT REMOVAL

1. Before the timing belt is removed, align the timing marks of the camshaft sprocket and crankshaft sprocket with the Number1 at the Top Dead Center of the compression stroke.





2.
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. Do not immerse parts in cleaning solvent.

Mark the belt running direction for reference in reinstallation.
NOTE:
If there is oil or water on any part, check the front case oil seal, camshaft oil seal, and water pump for leaks.

NOTE:
After the timing belt is removed, do not turn the crankshaft sprocket and the camshaft sprocket.

[[C]] IDLER PULLEY REMOVAL





CAUTION:
Because of the shallow hexagon hole of the hexagon socket head bolt, firmly insert the tool and carefully work not to damage the hexagon hole.

Remove the idler pulley using a hexagon wrench with 8 mm width across flats.

[[D]] CAMSHAFT SPROCKET BOLT REMOVAL





Use special tools MB990767 and MD998719 to prevent the camshaft sprocket from turning, and then loosen the camshaft sprocket bolt.

INSTALLATION SERVICE POINTS

]]A[[ CAMSHAFT SPROCKET BOLT INSTALLATION





Use special tools MB990767 and MD998719 to prevent the camshaft sprocket from turning, and then tighten the camshaft sprocket bolt.
Tightening torque: 90 ± 10 Nm (65 ± 7 ft-lb)


]]B[[ CRANKSHAFT SPROCKET INSTALLATION





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

3. Install the crankshaft sprocket to the crankshaft.

]]C[[ IDLER PULLEY INSTALLATION





CAUTION:
Because of the shallow hexagon hole of the hexagon socket head bolt, firmly insert the tool and carefully work not to damage the hexagon hole.

Install the idler pulley using a hexagon wrench with 8 mm width across flats.

]]D[[ TIMING BELT INSTALLATION

CAUTION:
Remove and install the timing belt, aligning the timing marks of the crankshaft sprocket and the camshaft sprocket with the Number1 at the Top Dead Center of the compression stroke.









1. Check the timing marks of the crankshaft sprocket and the camshaft sprocket are aligned with the Number1 at the Top Dead Center of the compression stroke. If they are not, align the timing marks again, paying attention to the interference between the valve and the piston.
2. Install the timing belt on each sprocket in the following sequence.
(1) Install the timing belt on the crankshaft sprocket and then on the water pump pulley, while tightening it to prevent slackness.
(2) Line up the timing marks of the left bank camshaft sprockets.
(3) Install the timing belt on the idler pulley, while taking up the slack.
(4) Install the timing belt on the right bank camshaft sprocket.
(5) Install the timing belt on the tensioner pulley.
3. Check to see that the timing marks of all the sprockets are in a alignment.





4. Using special tool MD998716, rotate the crankshaft a quarter of a turn counterclockwise.
Then rotate it back clockwise to verify that all the timing marks are in alignment.
5. Pull out the pin of the auto-tensioner.
6. Rotate the crankshaft two turns clockwise and leave it alone for approximately five minutes.









7. Check that the projection of the rod of the auto-tensioner is within the standard value.
Standard value: 9.1 - 13.4 mm (0.36 - 0.52 inch)


]]E[[ AUTO-TENSIONER INSTALLATION

CAUTION:
Always bleed the auto-tensioner of air before installing the auto-tensioner. (Refer to Air bleeding method)