2003 neon how to change tension pulley

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

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Filed Under (Mitsubishi Manuals) by admin on 14-01-2012

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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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2002 HONDA ACCORD – Timing Belt and Balancer Belt Installation Instructions

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Filed Under (Honda Manuals) by admin on 22-01-2011

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1. Remove and clean the balancer belt drive pulley. 2. Clean the timing belt pulleys, and the upper and lower timing cover. 3. Set the crankshaft to TDC. Align the dimple (A) on the tooth of the timing belt drive pulley with the pointer (B) on the oil pump. 4. Clean the camshaft pulley and set it to TDC. 5. Install the timing belt in a counterclockwise sequence, starting with the drive pulley. -1 The ”UP” mark (A) on the camshaft pulley should be at the top. -2 Align the TDC grooves (B) on the pulley with the top edge of the head. -1 Drive pulley (A). -2 Tensioner pulley (B). -3 Water pump pulley (C). -4 Camshaft pulley (D). 6. Loosen and retighten the adjusting nut to tension the timing belt. 7. Clean any oil off both faces of the balancer belt drive pulley. 8. Check the lower cover rubber seal for cracks and other damage. NOTE: ?If the rubber seal is coming off, apply liquid gasket to the lower cover and reinstall the rubber seal. Wipe off any liquid gasket that is pressed out. ?When replacing the rubber seal, clean the lower cover groove, cut the repair rubber seal to length, and put the rubber seal into the groove evenly. 9. Install the balancer belt drive pulley and the lower cover. 10. Temporarly install the crankshaft pulley and bolt. 11. Rotate the crankshaft pulley five or six turns counterclockwise to seat the timing belt on the pulleys. 14. Check the camshaft pulley marks. ?If the camshaft pulley marks are also at TDC, go to step 15. ?If the camshaft pulley marks are not at TDC, remove the timing belt and repeat steps 3, 4 and 5. 15. Remove the crankshaft pulley and the lower cover. 16. Turn the crankshaft to TDC again. 17. Lock the timing belt adjuster arm in place with one of the 6 mm timing cover bolts. 18. Loosen the adjusting nut 2/3-1 turn, and make sure the balancer belt tensioner moves freely. Then push the tensioner up and retighten the adjusting nut. 19. Align the rear balancer shaft pulley with a 6 x 100 mm bolt (or equivalent). -1 Remove the bolt (A) and washer (B) from the maintenance hole (C). -2 Scribe a line on a 6 x 100 mm bolt, 74 mm (2.9 in) from the end

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2004 Mitsubishi Lancer O-Z Rally TIMING BELT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Mitsubishi Manuals) by admin on 06-06-2012

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Fig. 79: Aligning Timing Belt Courtesy of MITSUBISHI MOTOR SALES OF AMERICA. 2. Loosen the tension pulley fixing bolt. 3. Place a screwdriver against the tensioner pulley and pry it fully back in the direction of the arrow. 4. Temporarily tighten the tensioner pulley bolt. 5. Remove the timing belt. Fig. 80: Tightening Tensioner Pulley Bolt Courtesy of MITSUBISHI MOTOR SALES OF AMERICA. INSTALLATION SERVICE POINTS >> A << TIMING BELT INSTALLATION CAUTION: If the timing belt is to be re-used, use chalk to mark (on its flat side) an arrow indicating the clockwise direction. CAUTION: After installing the timing belt, try to rotate the camshaft sprocket in the reverse direction. Recheck to be sure that the belt is fully tensioned and that each timing mark is in the proper position. 1. With the timing belt tensioner pulley bolt loosened, use a screwdriver to pry the tensioner pulley as close to the engine mount as possible. Then temporarily tighten tensioner bolt. Fig. 81: Adjusting Timing Belt Tensioner Courtesy of MITSUBISHI MOTOR SALES OF AMERICA. 2. Align each of the camshaft and crankshaft sprocket timing marks. 3. Install the timing belt in the following order, while making sure that the tension side of the belt is not loose. 1. Crankshaft sprocket 2. Water pump sprocket 3. Camshaft sprocket 4. Tensioner pulley >> B << TIMING BELT TENSION ADJUSTMENT 1. Initially loosen the fixing bolt of the tensioner pulley fixed to the engine mount side by 1/4-1/2 turn, and use the force of the tensioner spring to apply tension to the belt. 2. Turn the crankshaft in the proper rotation direction (clockwise) for two rotations, and recheck to be sure that the timing marks on each sprocket are aligned.

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Peugeot 306 Timing belt replacement Removal And Installation Manual

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Filed Under (Peugeot Manuals) by admin on 23-02-2011

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Removal Removal Raise and support front of vehicle. 1. Remove: RH front wheel. Engine undershield (if fitted). Lower inner wing panel. Auxiliary drive belt(s). 307: Engine tie-bars. Crankshaft pulley [1] . Timing belt upper cover [2] . Timing belt centre cover [3] . Timing belt lower cover [4] . 2. Turn crankshaft to setting position. Insert timing pins in camshaft sprocket and flywheel [5] & [6] . 3. Slacken tensioner nut to release tension on belt [7] . Lightly tighten nut. 4. Remove timing belt. 5. Installation – -1997 Installation – -1997 Ensure timing pins located correctly [5] & [6] . 1. Fit timing belt in following order: Crankshaft sprocket. Camshaft sprocket. Water pump sprocket. 2. Manufacturer: Peugeot Model: 306 (93-97) 1,4 Engine code: TU3M/Z (KDZ) Output: 55 (75) 5800 Tuned for: R-Cat Year: 1993-97 – Tensioner pulley. NOTE: Ensure belt is taut between sprockets on non-tensioned side. Slacken tensioner nut [7] . Turn tensioner anti-clockwise to tension belt. Temporarily tighten nut. 3. Remove timing pins [5] & [6] . 4. Attach tension gauge to belt at [8] . Tool No.(-).0192/SEEM C.Tronic 105.5. 5. Slacken tensioner nut [7] . 6. Tension belt as follows: 7. Turn tensioner anti-clockwise until tension gauge indicates 45 SEEM units. 8. Tighten tensioner nut to 20 Nm [7] . 9. Remove tension gauge. 10. Turn crankshaft four turns clockwise to setting position. 11. Ensure timing pins can be inserted [5] & [6] . 12. Wait 1 minute to allow belt to settle. 13. Apply firm thumb pressure to belt at . 14. Attach tension gauge to belt at [8] . Tool No.(-).0192/SEEM C.Tronic 105.5. 15. Slacken tensioner nut [7] . 16. Turn tensioner anti-clockwise to tension belt. New belt: 40 SEEM units. Used belt: 36 SEEM units. 17. Tighten tensioner nut to 20 Nm [7] . 18. Remove tension gauge [8] . 19. Turn crankshaft two turns clockwise. 20. Ensure flywheel timing pin can be inserted [6] . NOTE: DO NOT allow crankshaft to turn anti-clockwise. 21. Attach tension gauge to belt at [8] . Tool No.(-).0192/SEEM C.Tronic 105.5. 22. Check tension gauge reading. New belt: 51±3 SEEM units. Used belt: 45±3 SEEM units. 23. Install components in reverse order of removal. 24. Tighten crankshaft pulley bolts to 8 Nm [9] . 25. Installation – 1997- Installation – 1997- Ensure timing pins located correctly [5] & [6] . 1. Fit timing belt in following order: Crankshaft sprocket. Camshaft sprocket. Water pump sprocket. Tensioner pulley. NOTE: Ensure belt is taut between sprockets on non-tensioned side. 2. Slacken tensioner nut [7] . Turn tensioner anti-clockwise to tension belt. Temporarily tighten nut. 3. Remove timing pins [5] & [6] . 4. Attach tension gauge to belt at [8] . Tool No.(-).0192/SEEM C.Tronic 105.5. 5. Slacken tensioner nut [7] . 6. Tension belt as follows: 7. Remove cylinder head cover. 8. Install valve spring compressor. Tool No.0132AE [10] . 9. Turn tensioner anti-clockwise until tension gauge indicates the following: Except 307: 31 SEEM units. 307: 44 SEEM units.

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1996 TOYOTA T100 ENGINE MECHANICAL TIMING BELT INSTALLATION

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Filed Under (Toyota Manuals) by admin on 24-09-2011

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1. INSTALL CRANKSHAFT TIMING PULLEY (a) Align the pulley set key with the key groove of the timing pulley and slide on the timing pulley. (b) Slide on the timing pulley, facing the flange side inward. 2. INSTALL NO. 1 IDLER PULLEY AND NO.2 IDLER PULLEY (a) Using a 10 mm hexagon wrench, install the No.1 idler pulley with the plate washer and bolt. Torque: 35 N·m (350 kgf·cm, 26 ft·lbf) (b) Check that the pulley bracket moves smoothly. (c) Install the No.2 idler pulley with the bolt. Torque: 40 N·m (400 kgf·cm, 30 ft·lbf) (d) Check that the pulley moves smoothly. 3. TEMPORARILY INSTALL TIMING BELT NOTICE: The engine should be cold. (a) Use the crankshaft pulley bolt to turn the crankshaft and align the timing marks on the crankshaft timing pulley and on the oil pump body. (b) Remove any oil or water on the crankshaft timing pulley, idler pulley and water pump pulley, and keep them clean. NOTICE: Only wipe the pulleys; do not use any cleansing agent. (c) Align the installation mark on the timing belt with the drilled mark of the crankshaft timing pulley. (d) Install the timing belt on the crankshaft timing pulley, No.1 idler and water pump pulleys. 4. INSTALL TIMING BELT GUIDE Install the guide, facing the cup side outward

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1995 Isuzu Trooper LS TIMING BELT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Isuzu Manuals) by admin on 13-05-2012

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TIMING BELT Removal 1. Disconnect negative battery cable. Remove air cleaner assembly. Remove upper fan shroud. Remove cooling fan assembly. Remove all accessory drive belts. 2. Remove fan pulley assembly. Remove crankshaft pulley bolt. Using Puller (J-8614-01) or equivalent, remove crankshaft pulley. Remove oil cooler hose from timing cover. Remove timing belt cover. Align all timing marks prior to belt removal. See Fig. 1 – Fig. 4 . Remove belt tensioner pusher and timing belt. Fig. 1: Aligning Timing Belt Sprockets (DOHC) Courtesy of ISUZU MOTOR CO. Installation 1. Ensure all timing marks are aligned. Install belt over one pulley at a time starting at crankshaft sprocket and working counterclockwise. Belt should go over tensioner last. Secure belt at each pulley during installation with pinch clips. See Fig. 5 . 2. Compress timing belt tensioner pusher and insert pin to retain pusher. Apply pressure to tensioner against belt, and install tensioner pusher. Tighten bolts to specification. See TORQUE SPECIFICATIONS . 3. Loosen tensioner pulley bolt. Apply pressure on belt by rotating tensioner. Tighten tensioner pulley bolt to specification.. See TORQUE SPECIFICATIONS . Remove pin from timing belt tensioner pusher. 4. Remove pinch clips from timing belt (if used). Install crankshaft pulley, tightening center bolt finger tight. Rotate crankshaft 2 turns clockwise. Ensure timing belt tensioner pusher rod protrudes proper

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Toyota LandCruiser 4.2TD Timing belt replacement intervals

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Filed Under (Toyota Manuals) by admin on 02-03-2012

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Timing belt replacement intervals The information relating to timing belt replacement intervals is additional to the main purpose of this CD, but is included to provide guidance to garages and for customer advice. Where possible the recommended intervals have been compiled from vehicle manufacturers’ information. In a few instances no recommendation has been made by the manufacturer and the decision to replace the belt must be made from the evidence of a thorough examination of the condition of the existing belt. Apart from the visible condition of the belt, which is explained fully later in this section, there are several other factors which must be considered when checking a timing belt: Is the belt an original or a replacement. 1. When was the belt last replaced and was it at the correct mileage. 2. Is the service history of the vehicle known. 3. Has the vehicle been operated under arduous conditions which might warrant a shorter replacement interval. 4. Is the general condition of other components in the camshaft drive, such as the tensioner, pulleys, and other ancillary components driven by the timing belt, typically the water pump, sound enough to ensure that the life of the replacement belt will not be affected. 5. If the condition of the existing belt appears good, can you be satisfied that the belt will not fail before the next check or service is due. 6. If the belt does fail, have you considered the consequences. If the engine is an INTERFERENCE type then considerable expensive damage may well be the result. 7. The cost of replacing a belt as part of a routine service could be as little as 5 to 10% of the repair cost following a belt failure. Make sure your customer is aware of the consequences. 8. If in doubt about the condition of the belt – RENEW it. 9. Removal Removal Remove timing belt cover [1]. 1. Turn crankshaft clockwise until timing marks aligned [2]. 2. Ensure timing marks aligned: 1KZ-T/TE: [3]. 3. 4. Remove: Automatic tensioner unit [6]. Tensioner pulley bolt [7]. Tensioner pulley [8]. Timing belt. 5. Installation Installation Check tensioner pulley for smooth operation [8]. Replace if necessary. 1. Remove dust cover. Check tensioner body for leakage or damage [6]. Check pushrod protrusion is 9,0-9,8 mm [9]. 2. Check pushrod does not move when pushed against a firm surface. If pushrod moves: Replace automatic tensioner unit. 3. Slowly compress pushrod into tensioner body until holes aligned. Use press. 4. Retain pushrod with 1,5 mm Allen key through hole in tensioner body [10]. Fit dust cover. 5. Ensure timing marks aligned [2]. 6. Ensure timing marks aligned: 1KZ-T/TE: [3]. 1HD-FT/1HD-FTE: [4]. 7. Fit timing belt in anti-clockwise direction, starting at lower sprocket. Ensure belt is taut between sprockets. 8. Fit tensioner pulley [8]. Tighten bolt to 34 Nm [7]. 9. Push tensioner pulley against belt. Install automatic tensioner unit [6]. Tighten bolts evenly to 13 Nm [5]. 10. Remove Allen key from tensioner body to release pushrod. 11. Turn crankshaft two turns clockwise. Ensure timing marks aligned [2] & [3] or [4]. 12. If not: Repeat installation and tensioning procedures. 13. Install components in reverse order of removal. 14. Reset timing belt replacement warning lamp as follows: 15. -Runner/Landcruiser: Remove grommet in speedometer housing. Depress switch using a thin screwdriver [11]. 16. Colorado: Remove speedometer housing. Remove screw indicated and insert in alternative location [12]. 17. Amazon: Lamp illuminates at 90,000 miles. Return vehicle to dealer.

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Toyota Starlet Timing belt replacement intervals

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Filed Under (Toyota Manuals) by admin on 15-01-2012

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Removal Removal Raise and support front of vehicle. 1. Support engine. 2. Remove: RH front wheel. Inner wing panel. Engine mounting and bracket. Auxiliary drive belt(s). Cylinder head cover. Timing belt upper cover [1] . 3. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure crankshaft pulley timing mark aligned [2] . 4. Check hole in camshaft sprocket aligned with mark on camshaft bearing cap [3] . 5. If not: Turn crankshaft one turn clockwise. 6. Remove: Crankshaft pulley bolt [4] . Use tool Nos.09213-14010 & 09330-00021. Crankshaft pulley [5] . Use tool No.09213-31021. Timing belt lower cover [6] . 7. Temporarily fit crankshaft pulley bolt [4] . 8. Ensure timing marks aligned [3] & [7] . 9. Slacken tensioner bolt [8] . Move tensioner away from belt and lightly tighten bolt. 10. Remove: Timing belt. Tensioner pulley and spring [9] & [10] . 11. Installation Installation Check tensioner pulley for smooth operation [9] . 1. Check free length of tensioner spring is 38,4 mm [10] . 2. Fit tensioner and spring. Ensure spring is connected correctly. 3. Push tensioner to left and lightly tighten bolt [8] . 4. Ensure timing marks aligned [3] & [7] . 5. Fit timing belt in anti-clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets. 6. Slacken tensioner bolt [8] . 7. Turn crankshaft two turns clockwise to TDC on No.1 cylinder. Ensure timing marks aligned [3] & [7] . 8. If not: Repeat installation and tensioning procedures. 9. Tighten tensioner bolt [8] . Tightening torque: 19 Nm. 10. Remove crankshaft pulley bolt [4] . 11. Install: Timing belt lower cover [6] . Crankshaft pulley [5] . 12. Install components in reverse order of removal. 13. Tighten crankshaft pulley bolt [4] . Tightening torque: 152 Nm. Use tool Nos.09213-14010 & 09330-00021. 14.

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

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Filed Under (Kia Motors Manuals) by admin on 16-07-2012

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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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2003 Lexus ES 300 TIMING BELT Removal And Installation Manual

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Filed Under (Lexus Manuals) by admin on 04-07-2012

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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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