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belt diagram 2007 saturn 3 6

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INSTALL THE HOUSING A. If not already done, remove the bulkhead deck rail (Photo 4) . B. Place the Housing Assembly onto the bedrails (Photo 5) . This is best accomplished with two people. Center it between the bedrails and leave about ?” of space between the bulkhead and the back of the Housing. Do not fasten the Housing in place. C. Lift the Lid on the Housing and lean it against the cab (Photo 6) . Place a rag between the Lid and cab to prevent scratches. D. Making sure to leave the Pull-Strap connected to the threaded shipping Stud, rotate the Lock Lever to the 10 o’clock position (Photo 7) . Photo 5 Photo 6 Photo 7 Photo 4 STEP 3: INSTALL THE TRACKS ON DECK RAIL E QUIPPED BEDS . A. Remove the End Caps from the deck rails (Photo 8) . B. Insert threaded rectangular blocks (2 each side Crew Max bed; 3 each side short/long bed). INSTALL THE TRACKS ON DECK RAIL E QUIPPED BEDS ( CONTINUED ) Note: The threaded hole is off-centered and the block must be inserted with the hole closest to the bottom (Photo 9) . Note: Tracks for 2007 Tundra truck beds are shipped with the clamp setups for both applications with and without “Deck Rail Systems”. Before proceeding with an application with deck rails, you must first remove the Clamps shown (Photo 10) . C. Lower the tailgate and place the driver’s side Track onto the bedrail (Photo 11) , and key it onto Housing Stem (Diagram 12) , being sure that the Handle is properly engaged into the Track. D. Using 1/4-20 x 1-1/4″ countersunk screws, loosely secure the Tracks to the threaded blocks (Photo 13) . Do not tighten. E. Use a #10-24 x 1/2″ truss head screw and Cargo Nuts to secure the Tracks to the Housing Stems (Photo 14) . Tighten these connections securely. F. With the driver’s side Track in place, repeat sub-steps B-E for the passenger’s side Track. INSTALL THE TAILGATE EXTRUSION A. Lower the tailgate and insert fi ve (5) plastic shims beneath the inside fl ange of the tailgate cap in the locations shown (Photo 15; Diagram 16) . B. Being careful not to strike the ends of the Tracks, close the tailgate and place the Tailgate Extrusion upon the edge of the tailgate, centering it between the Tracks (Photo 17) . C. While holding the Tailgate Extrusion in place, use a #8 x 3/4″ self tapping screw and power screw gun to secure the center hole. (Photo 18) D. Lower the tailgate and hold the Tailgate Extrusion tight and square to the tailgate. Secure each end hole (Photo 19) making sure the screw passes through the shim described in Step (A) above. Secure the two remaining holes


INSPECTION When inspecting serpentine drive belts, small cracks that run across the ribbed surface of the belt from rib to rib are considered normal. If the the cracks are running along the rib (rather across), this is not normal and the belt(s) must be replaced. ADJUSTMENT It is not necessary to adjust belt tension on the 5.2L or 5.9L engines and on the 2.5L and 4.0L engines (without power steering). These engines are equipped with an automatic tensioner. The tensioner maintains correct tension at all times. 2.5L and 4.0L Engines With Power Steering See Figures 1, 2, 3 and 4 If the vehicle is not equipped with power steering, it will be equipped with an idler pulley. If equipped with an idler pulley, refer to and follow the 5.2L/5.9L belt removal and installation procedure. Loosen the pump upper pivot bolt, lower locknut and pump adjusting bolt using a ratchet and 13mm socket or a 13mm box wrench. 1. Use a belt tension gauge placed in the middle of the belt being tested. Proper tension for a new belt is 180-200 lbs. (800-900 N) and 140-160 lbs. (623-712 N) for a used belt. 2. Tighten the pump adjusting bolt to achieve proper tension and recheck the belt tension. 3. Fig. Fig. 1: Loosen the pivot bolt (1), then the locking bolt (2) to loosen the power steering pump from behind Fig. Fig. 2: Use a ratchet and 13mm size socket to rotate the power steering pump Fig. Fig. 3: Adjustment points on the 2.5L engines without power steering (rear view) Fig. Fig. 4: Adjustment points on the 2.5L engine (front view) Removal & Installation 2.5L and 4.0L Engines With Power Steering See Figures 5, 6 and 7 Fig. Fig. 5: Proper belt routing diagram can usually be found on a sticker located in the engine compartment Fig. Fig. 6: Common 4.0L engine serpentine belt routing Fig. Fig. 7: Common 2.5L engine serpentine belt routing Loosen the rear power steering pump mounting bolts using a ratchet and 13mm socket or a 13mm box wrench. 1. Loosen the pump upper pivot bolt, lower locknut and the pump adjusting bolt using a ratchet and 13mm socket or a 13mm box wrench. 2. Remove the belt. 3. To install: Install the belt. 4. Tighten the pump adjusting bolt to achieve proper tension. 5. Install the pump rear mounting bolts, pivot bolt and locknut. Tighten the bolts to 20. ft. lbs. (27 Nm). 6. Check the belt for proper tension. If tension is incorrect, refer to the adjustment procedure in this section. 7. 5.2L and 5.9L Engines See Figures 8, 9 and 10

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

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


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.


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