Removal and installation of the timing belt of the K4M engine

All operations are conventionally shown on a removed engine, since the engine may be fitted to different types of vehicles.

Removing the timing belt

Remove the intake hose.

Remove the intake silencer.

Operations common to all vehicle specifications.

Remove the accessory drive belt.

Remove the crankshaft pulley.

1. Unscrew the plug 1 (Figure 1) of the TDC locking pin hole (Torx E14 socket, extension, ratchet wrench).

2. Unscrew the upper timing cover retaining bolts and nuts 1 (Figure 2) (13 mm sockets, ratchet wrench).
3. Remove the upper timing cover 2.

4. Unscrew the lower timing cover retaining bolts 1 (Figure 3) (8 mm socket, ratchet wrench).
5. Remove the lower timing cover 2.

6. Slacken the tensioner roller axle nut 1 (Figure 4) (16 mm socket, ratchet wrench).
7. Unscrew the idler roller retaining bolt 5 using the tool (Mot1368 tool, Torx T50 socket, ratchet wrench).
8. Remove the idler roller 4.
9. Remove the timing belt 3.
10. Unscrew the tensioner roller axle nut 1 (16 mm socket, ratchet wrench).
11. Remove the timing belt tensioner roller 2.
12. Remove the crankshaft toothed pulley 6.

Important! Parts that must be replaced:

• timing belt;
• timing belt tensioner roller;
• timing belt idler roller;
• crankshaft pulley retaining bolt;
• inlet camshaft plug;
• exhaust camshaft plug.

Important! Before fitting the crankshaft pulley, degrease the pulley support surface and the crankshaft nose.

Fitting the timing belt

1. Position the camshaft slots 1 (Figure 5) horizontally and offset downwards from the shaft axes, turning the camshafts if necessary using the tool (Mot1496 tool, 16 mm socket, extension, ratchet wrench).

2. Fit the timing setting tool 1 (Figure 6) onto the engine and secure it with bolt 2 (Mot1496 tool, 10 mm socket, extension, handle).
3. Position the marks on the spokes of the camshaft toothed pulleys vertically upwards.
4. Fit the new timing belt tensioner roller 2 (Figure 4), engaging its lug in the slot.
5. Screw in the tensioner roller axle nut 1 without tightening (16 mm socket, ratchet wrench).
6. Fit the crankshaft toothed pulley 6.
7. Fit the new timing belt 3.
8. Fit the new timing belt idler roller 4. Timing belt idler roller retaining bolt 5 tightening torque — 50 N·m (5.0 kgf·m) (Mot1368 tool, 16 mm socket, torque wrench).

9. Using a 6 mm hex key, align the moving pointer (A) (Figure 7) with the notch (B) of the fixed pointer by turning the eccentric 1 clockwise.
10. Tighten the timing belt tensioner roller nut to a torque of 7 N·m (0.7 kgf·m) (16 mm socket, torque wrench).
11. Fit the lower timing cover 2 (Figure 3). Lower timing cover retaining bolts 1 tightening torque — 12 N·m (1.2 kgf·m) (8 mm socket, torque wrench).

12. Fit the TDC locking pin 1 (Figure 8) onto the cylinder block (Mot1489 or 67.7820-9701L TDC locking pin).
13. Fit the crankshaft pulley.
14. Unscrew the Mot1496 tool retaining bolt 2 (Figure 6) and remove the timing setting tool 1 (10 mm socket, extension, handle).
15. Remove the TDC locking pin from the cylinder block (Mot1489 or 67.7820-9701L TDC locking pin).

Checking the timing belt tension

1. Turn the crankshaft two revolutions clockwise (viewed from the timing belt side) until the previously made marks align (on the phaser pulley), fit the TDC locking pin onto the cylinder block.
2. Carefully bring the crankshaft to the stop against the locking pin (18 mm socket, ratchet wrench).
3. Remove the TDC locking pin from the cylinder block (Mot1489 or 67.7820-9701L TDC locking pin).
4. Make sure that the moving pointer (A) (Figure 7) is located opposite the notch (B) of the fixed pointer. If this is not the case:
   • unscrew the tensioner roller nut 1 (Figure 4) by no more than one turn, holding the moving pointer with a 6 mm hex key (16 mm socket, ratchet wrench);
   • smoothly bring the moving pointer into alignment with the notch by turning the eccentric clockwise.
5. Tighten the timing belt tensioner roller nut to a torque of 27 N·m (2.7 kgf·m) (16 mm socket, torque wrench).

Checking the valve timing

Before checking the valve timing, make sure that the moving pointer (A) (Figure 7) of the tensioner roller and the notch (B) of the fixed pointer are correctly positioned.

1. Fit the TDC locking pin 1 (Figure 8) onto the cylinder block (Mot1489 or 67.7820-9701L TDC locking pin).
2. Carefully bring the crankshaft to the stop against the locking pin (18 mm socket, ratchet wrench).
3. Fit (without applying force) the timing setting tool 1 (Figure 6) (the slots at the ends of the camshafts 1 (Figure 5) must be horizontal and offset downwards from the shaft axes) (Mot1496 tool).
4. If the Mot1496 tool does not seat, the valve timing must be set again and the timing belt tension adjusted.
5. Remove the Mot1496 timing setting tool.
6. Remove the TDC locking pin from the cylinder block (Mot1489 or 67.7820-9701L TDC locking pin).
7. Fit the window cover on the lower timing cover, making sure that the pin enters the notch.

Operations common to all vehicle specifications:

• Apply sealant to the thread of the TDC locking pin hole plug 1 (Figure 1) and screw in the plug. Plug tightening torque: 20 N·m (2.0 kgf·m) (Torx E14 socket, torque wrench).
• Fit the right-hand engine mounting.
• Fit the crankshaft pulley.
• Fit the auxiliary drive belt.
• Fit the intake hose.
• Fit the intake silencer.