Timing Belt Idler Pulley: Service and Repair

Timing Belt Idler Pulley Replacement

Special Tools
* KM-6333 Fixing Rod
* MK-6340 Locking Tool
* KM-6625 Flywheel Locking Device

Removal Procedure




1. Open the hood.
Warning: Refer to Battery Disconnect Warning (Service Precautions).

2. Disconnect the battery.

* Detach the negative connection from the ground terminal.
* Loosen the nut.

3. Remove the air cleaner housing. Refer to Air Cleaner Inlet Duct Replacement (Service and Repair).
4. Remove the front toothed belt cover (top). Refer to Timing Belt Upper Front Cover Replacement (Service and Repair).
5. Raise the vehicle by its full height.
6. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (Service and Repair).
7. Set the engine to "TDC".
Set torsional vibration balancer in direction of engine rotation to "1st cylinder TDC" (mark 1).
8. Lower the vehicle by its full height.





Note: Recognizable from the lettering "Right" (arrow).

9. Prepare the right half of MK-6340 for use on the U 18 XER engines.

* Detach the front panel (1) from MK-6340 .
* Remove the 2 bolts (2).




10. Insert MK-6340 into the camshaft timing gears.

* Insert MK-6340 (1, 2) in the camshaft adjuster as shown

Note: The spot-type marking (4) on the intake camshaft adjuster does not correspond to the groove of MK-6340 during this process but must be somewhat above as shown.

* The spot type marking (3) on the exhaust camshaft adjuster must correspond to the groove on MK-6340 .

11. Raise the vehicle by its full height.




12. Block the crankshaft.

* Detach the screwed connection (1).
* Insert KM-6625 (2).
* Tighten the screwed connection (3).




13. Remove the torsional vibration damper (1).
Remove the bolt (2).
14. Remove the lower part of the toothed belt cover (3).
Remove the 4 bolts (4).




15. Block the toothed belt tensioner.
Apply tension to the toothed belt tensioner (2) in the direction of the arrow, using an Allen key (1). Fix using KM-6333 (3).
16. Remove the toothed belt.
17. Remove the toothed belt guide roller.
Remove the bolt.

Installation Procedure




1. Clean the thread, toothed belt guide roller.

Caution: Refer to Fastener Caution (Fastener Caution).

Note: Use assembly tool.

2. Install the toothed belt guide roller.
Use a new bolt.

Tighten the bolt to 25 Nm (18 lb ft).

3. Insert the toothed belt.
4. Release tension on the toothed belt tensioner.

* Apply preliminary tension clockwise to the toothed belt tension roller.
* Remove KM-6333 .
* Toothed belt tension pulley automatically moves to the correct position.

5. Raise the vehicle by its full height.
6. Install the front toothed belt cover (lower).

Tighten the 4 bolts to 6 Nm (53 lb in).

Note: The new bolt must be coated with screw locking compound (red).

7. Install the torsional vibration balancer.
Use a new bolt.

Tighten the bolt to 95 Nm (70 lb ft) plus 30 degrees, plus 15 degrees.

8. Remove KM-6625 .

* Detach the screwed connection.
* Tighten the bolted connection.
* Use new nuts.

9. Lower the vehicle by its full height.
10. Remove MK-6340 .
11. Timing, Inspection

Note: Note marking, camshaft sprockets.

* Turn the crankshaft 720 degrees in the direction of engine rotation by the bolt on the torsional vibration damper.
* Insert MK-6340 (1, 2) in the camshaft adjuster as shown.

Note: The spot-type marking (4) on the intake camshaft adjuster does not correspond to the groove of MK-6340 during this process but must be somewhat above as shown.

* The spot type marking (3) on the exhaust camshaft adjuster must correspond to the groove on MK-6340 .

12. Raise the vehicle by its full height.




13. Inspect crankshaft position.
Markings on torsional vibration damper and lower part of toothed belt cover (marking 1) must align.
14. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (Service and Repair).
15. Lower the vehicle by its full height.
16. Remove MK-6340 .
17. Install the front toothed belt cover (top). Refer to Timing Belt Upper Front Cover Replacement (Service and Repair).
18. Install the air cleaner housing. Refer to Air Cleaner Inlet Duct Replacement (Service and Repair).
19. Connect the battery.
Attach the negative connection to the ground terminal.

Tighten the nut to 5 Nm (44 lb in).

20. For programming procedures, refer to Control Module References (Programming and Relearning).
21. Close the hood.