TIMING BELT REMOVAL/INSTALLATION [MZR-CD (RF Turbo)]

Warning

• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injures or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure". (See BEFORE SERVICE PRECAUTION [MZR-CD (RF Turbo)].)

1. Disconnect the negative battery cable.

2. Remove the splash shield (RH).

3. Remove the drive belt. (See DRIVE BELT REPLACEMENT [MZR-CD (RF Turbo)].)

4. Remove in the order shown in the table.

5. Install in the reverse order of removal.

6. Start the engine and inspect the pulleys and the drive belt for runout and contact.

N0.3 Engine Mount Removal Note

1. Suspend the engine using the SSTs.

Lower Timing Belt Cover Removal Note

Caution

• The timing belt cover could be damaged easily. Hold the timing belt cover at the locations indicated in the figure and remove the crankshaft position sensor harness slowly.

Timing Belt, Timing Belt Auto Tensioner Removal Note

1. Turn the crankshaft clockwise and align the timing marks as shown.

Caution

• Forcefully twisting the belt, turning it inside out, or allowing oil or grease on it will damage the belt and shorten its life.

• After removing the timing belt, do not move the crankshaft and/or camshaft pulley from this position because it can cause the valve and piston to contact.

2. Remove the timing belt auto tensioned.

3. Mark the timing belt rotation on the belt for proper reinstallation.

Timing Belt, Timing Belt Auto Tensioner Installation Note

1. Measure the tensioned rod projection length.

• If not as specified, replace the auto tensioned.

2. Inspect the auto tensioned for oil leakage.

• If not as specified, replace the auto tensioned.

Projection (Free length)

12.9-14.6 mm. {0.508-0.574 in}

Caution

• Placing the auto tensioner horizontally can cause oil leakage and damage the auto tensioner. Place the auto tensioner vertically when using a vise.

3. Verify the thrust of the auto tensioner rod in the following order:

• If the tensioner rod is rigid when it is pushed with a force of approximately 235 N {24 kgf, 53 Ibf}, push it down slowly and fix the pin in the hole.

• If there is no resistance on the tensioner lod and it moves slightly when it is pushed with a force of approximately 235 N {24 kgf, 53 Ibf};

(1) Push it down slowly two or three times to the bottom end of the rod.

(2) If the rod protrudes approximately 8.1 mm {0.32 in}, verify that there is resistance on the tensioner lod.

Caution

• To prevent damage to the inside of the auto tensioner, do not press down the auto tensioner rod with a force greater than the specified 235 N {24 kgf, 53 lbf}.

Be careful that the rod does not touch the bottom.

• If the rod protrudes is restored, push it down slowly and fix the pin in the hole.

- If the resistance is not restored, replace the auto tensoner.

Caution

• To prevent the bolts (M8 x 1.25) from damaging the fuel injection pump and pulley, do not fully tighten the fixing bolts. If it contacts the pulley surface, it will damage the pulley.

4. Verify that all timing marks are correctly aligned.

5. Fix the camshaft pulley to the cylinder head using bolt (M8 x1.25).

6. Fix the injection pump pulley to the bracket using two bolts (M8 x1.25).

• If not, align all timing marks according to the procedure below.

Caution

• Turn the crankshaft in the direction which will prevent the TDC and BDC from being passed. Otherwise it can cause the valve and piston to contact.

(1) Turn the crankshaft and set it an angle of 45° or more away from the TDC and BDC.

(2) Align the timing marks of the camshaft pulley.

(3) Align the timing marks of the injection pump pulley.

(4) Turn the crankshaft and align the timing marks of the timing belt pulley.

7. Install the timing belt on the pulleys in the order described below.

(1) Timing belt pulley

(2) Idler

(3) Injection pump pulley

(4) Camshaft pulley

(5) Water pump pulley

(6) Tensioner

8. Remove the injection pump pulley fixing bolts and camshaft pulley fixing bolt (M8 x 1.25).

9. Hand tighten the auto tensioner bolts in the order A to B as indicated in the figure.

10. Tighten the auto tensioner bolts in the order A to B as indicated in the figure.

Tightening torque

19-25 N·m {1.9-2.6 kgf·m, 14-18 ft·lbf}

11. Remove the pin from the auto tensioner to apply tension to the belt.

12. Turn the crankshaft clockwise twice, and align the timing marks.

13. Verify that all timing marks are correctly aligned.

• If not as specified, repeat from Timing Belt, Timing Belt Auto Tensioner Removal Note.

Crankshaft Pulley Installation Note

1. Tighten the bolts in the order shown.

Tightening torque

23-32 N·m {2.3-3.3 kgf·m, 17-23 ft·lbf}

No.3 Engine Joint Bracket Installation Note

1. Tighten the No.3 engine joint bracket bolt and nut in the order shown.

Tightening torque

75-104 N·m {7.7-10.6 kgf·m, 56-76 ft·lbf}