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2003 Kia Optima L4-2.4L Timing Belt Service and Repair Manual

Posted by on 16 July 2012, 11:43 pm

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3.Turn the crankshaft clockwise and align the timing marks so as to bring the No.1 cylinder to compression top-dead-center position. At this time the timing marks of the camshaft sprocket and the upper surface of the rocker cover should coincide, and the dowel pin of the camshaft sprocket should be at the upper side. Remove the auto tensioner. CAUTION: Rotate the crankshaft clockwise. 4.Remove the timing belt. NOTE: If the timing belt is reused, make an arrow mark indicating the turning direction (or the front of the engine) to make sure that the belt is reinstalled in the same direction as before 6.When the oil pump sprocket nut is removed, first remove the plug at left side of the cylinder block and insert a screwdriver to check the left counter balance shaft in position. Screwdriver used for this purpose should have a shaft 8 mm (0.3 inch) in diameter which can be inserted more than 60 mm (2.36 inch) 7.Remove the oil pump sprocket retaining nut and remove the oil pump sprocket. 8.Loosen the right counter balance shaft sprocket mounting bolt until it can be loosened by hand. 9.Next, remove tensioner “B” and remove timing belt “B”. CAUTION: After timing belt “B” has been removed, do not attempt to loosen bolt while holding sprocket with pliers, etc. 10.Remove the crankshaft sprocket “B” from crankshaft. INSPECTION Sprockets, Tensioner Pulley, and Idler Pulley 1.Check the camshaft sprocket, crankshaft sprocket, tensioner pulley, and idler pulley for abnormal wear, cracks, or damage. Replace as necessary. 2.Inspect the tensioner pulley and the idler pulley for easy and smooth pulley rotation and check for play or noise. Replace as necessary. 3.Replace if there is grease leak

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2002 Mitsubishi Montero Limited Removing Drive Belt Auto Tensioner/ Aligning Timing Marks

Posted by on 14 January 2012, 11:44 am

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Aligning Timing Marks (2001-02 Montero) Courtesy of MITSUBISHI MOTOR SALES OF AMERICA. Installation (2001-02 Montero) 1. Place auto-tensioner in soft-jawed vise to SLOWLY compress the push rod. If there is a plug at the base of the auto-tensioner body, place flat washer around plug so it will not contact vise jaw. 2. Slowly compress auto-tensioner push rod until holes in push rod and auto-tensioner housing are aligned. Insert a locking pin into the alignment holes. Install auto-tensioner on engine. 3. Ensure all timing marks are still aligned. See Fig. 11 . Install timing belt on crankshaft sprocket, idler pulley, left bank camshaft sprocket, water pump pulley, right bank camshaft sprocket, and tensioner CAUTION: Never compress the auto-tensioner too fast, or the push rod will be damaged. WARNING: Right bank camshaft can easily turn from applied spring pressure. Be careful not to pinch fingers when installing timing belt. 2002 Mitsubishi Montero Limited MITSUBISHI 3.5L V6 – SOHC many waters gallery pulley. Take all slack out of timing belt. 4. Loosen the tensioner pulley center bolt. Using Tensioner Pulley Wrench (MD998767), rotate tensioner pulley against timing belt. Temporarily tighten tensioner pulley center bolt. Using Crankshaft Pulley Spacer (MD998769), turn crankshaft 1/4 turn counterclockwise. Turn crankshaft 1/4 turn clockwise. Ensure all timing belt marks are still aligned. 5. Loosen tensioner pulley center bolt. Position tensioner pin holes at bottom of tensioner. Install Tensioner Pulley Wrench (MD998767) on tensioner pulley. See Fig. 12 . Using torque wrench, apply 39 INCH lbs. (4.4 N.m) of torque (counterclockwise direction) to tensioner pulley. Tighten tensioner center bolt to specification while holding tensioner pulley stationary. See TORQUE SPECIFICATIONS . 6. Remove locking pin from auto-tensioner. Turn crankshaft 2 revolutions clockwise and align all timing marks. DO NOT rotate counterclockwise. 7. Wait for at least 5 minutes, then check auto-tensioner push rod protrusion. To check push rod protrusion, measure clearance between body of auto-tensioner and bottom of tensioner pulley bracket arm. Clearance should be 0.15-0.20″ (3.8-5.0 mm). If protrusion is not correct, repeat timing belt tensioning procedure. Ensure all timing marks are aligned. 8. Install timing belt covers. See Fig. 10 . Install crankshaft pulley. Tighten crankshaft pulley bolt to specification. See TORQUE SPECIFICATIONS . Install accessory mount assembly on front of engine. See Fig. 13 . See TORQUE SPECIFICATIONS . To install remaining components, reverse removal procedures. See Fig. 7 and Fig. 8 . Adjust drive belts to proper tension. 9. When filling cooling system, use 50/50 mix of coolant and water. Open bleed screw on top of thermostat housing. Slowly fill cooling system until coolant flows out of bleed hole. Install bleed screw. Start engine and run to normal operating temperature. Race engine to 3000 RPM several times. Stop engine. After engine cools, refill radiator and coolant reservoir tank.

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1997 Chrysler Sebring JXi TIMING BELT REMOVAL AND INSTALLATION MANUAL

Posted by on 16 July 2012, 11:43 pm

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1. Disconnect negative battery cable from jumper terminal. Raise and support vehicle. Remove right front wheel. Remove accessory drive belt splash shield from right wheelwell. 2. Remove accessory drive belts. Remove right engine support assembly vertical bolts from bottom side of frame rail (timing belt end of engine). 3. Lower vehicle. Place floor jack under vehicle to support weight of engine and transaxle assembly. Remove 3 bolts attaching engine support assembly to engine block bracket. 4. Move the A/C drier aside with hoses attached. Remove coolant reservoir tank. Remove right engine support assembly. Remove 3 bolts attaching engine support bracket to engine block, and remove bracket. 5. Remove crankshaft vibration damper. Remove power steering pump (hoses attached) and bracket from engine block. Remove timing belt covers. 6. Rotate crankshaft to align camshaft and crankshaft timing marks. 7. If reusing old timing belt, mark timing belt direction of rotation for installation reference. Loosen timing belt automatic tensioner bolts. Remove timing belt. Remove automatic tensioner. Installation 2.5L VIN H (Cirrus, Sebring Convertible & Stratus) 1. Place automatic tensioner into vise, and SLOWLY compress plunger. When plunger is compressed into tensioner body, install locking pin through body and plunger holes to retain plunger until tensioner is installed. See Fig. 13 . 2. Index tensioner in vise the same direction as installed. This will ensure proper pin orientation when tensioner is installed in engine.

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TIMING BELT COMPONENTS FOR REMOVAL AND INSTALLATION MANUAL

Posted by on 13 July 2012, 11:43 pm

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TIMING BELT REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE ENGINE UNDER COVER 3. REMOVE AIR CLEANER DUCT 4. REMOVE DRIVE BELT, FAN WITH FLUID COUPLING AND WATER PUMP PULLEY (See step 5 in water pump removal in Cooling System) 5. REMOVE RADIATOR ASSEMBLY (See steps 5 and 6 in radiator removal in Cooling System) 6. REMOVE NO.3 TIMING BELT COVER (a) Remove the oil filler cap. (b) Using a 5 mm hexagon wrench, remove the 6 bolts and belt cover. 7. REMOVE NO.2 TIMING BELT COVER Using a 5 mm hexagon wrench, remove the 3 bolts, belt cover and gasket. If you are unable to loosen the bolt on the right because the PS pump pulley interferes with the hexagon wrench, first remove the pulley as follows. (a) Using SST to hold the pulley, remove the nut. SST 09960-10010 (b) Remove the pulley. 8. REMOVE DRIVE BELT TENSIONER Remove the 3 bolts and tensioner. – ENGINE ENGINE MECHANICAL EG-19 9. SET NO.1 CYLINDER TO TDC/COMPRESSION (a) Turn the crankshaft pulley, and align its groove with timing mark “0″ of the No.1 timing belt cover. NOTICE: Always turn the crankshaft clockwise. (b) Check that the timing marks of the camshaft timing pulleys are aligned with the timing marks of the No.4 timing belt cover. If not, turn the crankshaft 1 revolution (360?). 10. REMOVE TIMING BELT FROM CAMSHAFT TIMING PULLEYS HINT (Re-using timing belt): Place matchmarks on the timing belt and camshaft timing pulleys as shown in the illustration. (a) Alternately loosen the 2 bolts, and remove them, the tensioner and dust boot. (b) Disconnect the timing belt from the camshaft timing pulleys. 11. REMOVE CAMSHAFT TIMING PULLEYS Using SST, remove the bolt for the timing pulley. Remove both timing pulleys. SST 09960-10010 (09962-01000, 09963-01000) 12. REMOVE CRANKSHAFT PULLEY (a) Using SST, loosen the pulley bolt. SST 09213-70010, 09330-00021 (b) Remove the SST and pulley bolt

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2003 Lexus ES 300 TIMING BELT Removal And Installation Manual

Posted by on 4 July 2012, 11:43 pm

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TIMING BELT Removal (ES 300) 1. Raise and support vehicle. Remove right side front wheel. Remove right fender apron seal. Remove accessory drive belts. Lower vehicle. Disconnect engine coolant reservoir hose from water outlet. Disconnect ground strap connectors. 2. Remove engine moving control rod and engine mounting bracket No. 2 (right side), located near timing belt cover. Remove generator-to-engine bracket for access to timing belt covers. 3. Using Pulley Holder (09213-54015) or equivalent and Handle (09330-00021) or equivalent, hold crankshaft pulley. Remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. Remove No. 1 and No. 2 timing belt covers and gaskets. See Fig. 1 . Remove transverse engine mounting bracket from front of engine. Note direction of timing belt guide installation for reassembly reference. Remove timing belt guide. 4. Temporarily install crankshaft pulley bolt and washer in crankshaft. Using crankshaft pulley bolt, rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 2 . 5. Ensure timing marks on camshaft sprockets are aligned with timing mark on No. 3 timing belt cover. See Fig. 2 . If timing marks are not aligned, rotate crankshaft clockwise one full revolution (360 degrees). Remove crankshaft pulley bolt. 6. If reusing old belt, ensure there are 3 installation marks and front arrow marked on belt. See Fig. 3 . If not, place mating mark on belt where it contacts the crankshaft and camshaft sprockets. Also, mark belt with arrow showing direction of rotation. 7. Alternately loosen 2 bolts, and remove timing belt tensioner and dust boot. DO NOT hold tensioner with push rod facing downward. Remove timing belt in the following sequence: No. 1 idler pulley, right camshaft sprocket (firewall side), No. 2 idler pulley, left camshaft sprocket (front of vehicle side), left camshaft sprocket (front of vehicle side), water pump pulley, then crankshaft sprocket

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