Necessary equipment
DW 110–060 Engine clamp
EN-48245 Timing Belt Adjuster - Camshaft Holder
EN-48246 Timing Belt Adjuster - Crankshaft Holder
Removal procedure
1. Disconnect the negative battery cable.
2. Remove decorative cover. See «Decorative cover» in this section.
3. Remove the hoses and ducts of the charge air system. See «Air injection system» in this section.
4. Remove the accessory belt. See «Accessory drive belt and tensioner» in this section.
Attention! Raise the engine just enough to take the load off the engine mount, otherwise damage to the mount and failure of the lifting equipment may result.
5. Support the motor assembly using the DW110-060 motor jig.
6. Remove damping engine mount block. See «Engine Mount Assembly (Right side)» in this section.
7. Remove the upper timing belt cover.
8. Remove the accessory drive belt tensioner.
9. Remove tensioner. See «Accessory drive belt and tensioner» in this section.
10. Remove the crankshaft pulley.
11. Remove the lower timing belt cover.
12. Remove the engine mount bracket.
13. Remove the timing belt tensioner.
14. Remove the timing belt.
15. Remove the camshaft sprocket.
Timing belt tension adjustment
1. Remove vacuum pump. See Part 1F1, Engine Controls - 2.0 Diesel.
2. By rotating the camshaft, align with the hole at the top point.
3. Rotating the crankshaft, align with the mark on the crankshaft sprocket.
4. Loosen the cap screw (a) holes for the crankshaft holder.
5. Insert the EN-48246 crankshaft holder into the hole (b) under the crankshaft holder.
Note: Slowly rotate the crankshaft sprocket while inserting the crankshaft holder.
6. Install the EN-48245 camshaft holder from the rear (c) camshaft.
7. Align the mark on the sprocket with the mark on the rear timing belt cover.
8. Install the camshaft sprocket and hand tighten the bolt.
9. Install the timing belt.
10. Install the timing belt tensioner by hand-tightening the bolt.
11. Turn hex wrench (a) counterclockwise to tighten the belt. Rotate until the point coincides with the notch (b).
12. After aligning with the notch, tighten the timing belt tensioner bolt.
13. Install the camshaft sprocket bolt.
Tighten
Tighten the timing belt tensioner bolt to 25 Nm (18.4 lb-in).
Tighten the camshaft sprocket bolt to 133 Nm (98.1 lb-in).
14. Remove the EN-48245 camshaft holder and EN-48246 crankshaft holder.
15. Rotate the crankshaft clockwise more than 2 cycles and check the mark on the crankshaft sprocket.
16. After aligning the timing belt, tighten the plug bolt of the hole for the crankshaft holder.
Tighten
Tighten the plug bolt of the hole for the crankshaft holder to 30 Nm (22.1 lb-ft).
Note: If there is no alignment with the TDC of No. 1 cylinder, repeat the above procedure for No. 4 ~ No. 10 until there is no alignment.
Attention! Since the installation of these special maintenance tools aims to align with the TDC of cylinder #1, if not aligned exactly, engine power and emissions will be affected.
Installation procedure
1. Install the engine mount bracket.
2. Install the lower timing belt cover.
3. Install the crankshaft pulley.
4. Install the accessory drive belt tensioner.
5. Install the upper timing belt cover.
Tighten
Tighten engine mount bracket bolts to 45 Nm (33.1 lb-ft).
Tighten the timing belt lower cover bolts to 11 Nm (97.4 lb-in).
Tighten the crankshaft pulley bolts to 34 Nm (25.1 lb-ft).
Tighten the accessory drive belt tensioner bolt to 52 Nm (38.4 lb-ft).
Tighten the timing belt upper cover bolts to 11 Nm (97.4 lb-in).
