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3406E TRUCK ENGINE 2WS Camshaft Gear Removal And Installation Manual

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Filed Under (More Manuals) by admin on 28-05-2012

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1. Verify that the timing mark on camshaft gear (1) is aligned with Timing Mark (X) on front housing (3) . 2. Remove top bolt (2) from camshaft gear (1) . Install Tooling (A) in place of the bolt. 3. Remove remaining bolts (2) and remove camshaft gear (1) . 4. NOTICE Do not turn the crankshaft or the camshaft while the camshaft gear is removed. If the front gear group is not correctly timed during installation, interference can occur between the pistons and the valves, resulting in damage to the engine. Remove Tooling (A) . 5. Installation Procedure Required Tools Tool Part Number Part Description Qty A 9U-6896 Guide Bolt 1. Align the hole in the back of camshaft gear (1) with the dowel in the adapter. Install camshaft gear (1) over Tooling (A) . Note: Camshaft timing is critical. The timing mark on the camshaft gear must be aligned with the timing mark on the front cover when the No. 1 piston is at the top center of the compression stroke. Refer to Testing and Adjusting, “Gear Group (Front) – Time”. Verify that the timing mark on camshaft gear (1) is aligned with Timing Mark (X) on front housing (3) . 3. Note: If the timing marks are not aligned, remove camshaft gear (1) and rotate the camshaft until the timing marks are aligned. Install bolts (2) . Remove Tooling (A) and install remaining bolt (2) . 4. 5. Check the backlash between the camshaft gear and the adjustable idler gear. The backlash should be 0.216 ± 0.114 mm (0.0085 ± 0.0045 inch). Refer to Testing and Adjusting, “Gear Group (Front) – Time” for the backlash adjustment procedure. 6. End By: Install the front cover. Refer to Disassembly and Assembly, “Front Cover – Install”

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2000-2002 Toyota Corolla, Celica, MR2 Spyder, and ECHO DTC P1349 – VVTi ACTUATOR Repair Manual

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Filed Under (Toyota Manuals) by admin on 27-04-2012

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TC P1349 – VVTi ACTUATOR – EG009-03 May 19, 2003 Page 3 of 4 1. Inspect the condition of the valve cover oil baffle as per TSB EG007-02. If camshaft or camshaft position sensor damage resulting from a bent baffle is identified, repair the damage as necessary. 2. Make sure the vehicle is in “PARK” with the engine idling. 3. Referring to the screen flow below, connect the Toyota Diagnostic Tester to the vehicle and select the VVT Control Bank One Active Test (VVT CTRL B1) from the Active Test Menu. 1: DATA LIST 2: DTC INFO 3: 4: SNAPSHOT 5: SYSTEM CHECK 6: RESET MEMORY 7: MONITOR INFO 8: CHECK MODE SELECT DATA B DIAGNOSTIC MENU ENGINE A C INJ VOL A/F CONTROL CAN CTRL VSV TANK BYPASS VSV EVAP VSV (ALONE) A/C MAG CLUTCH FUEL PUMP/SPD LINE PRESS UP VVT CTRL B1 Confirm that the Vehicle is Stopped And Engine Idling 3: ACTIVE TEST PRESS [ENTER] INJECTOR 3.5ms IGN ADVANCE 11.0deg CALC LOAD 22% MAF 3.68gm/s ENGINE SPD 684rpm COOLANT TEMP186.8F INTAKE AIR 129.2F THROTTLE POS 14% CTP SW ON VEHICLE SPEED0MPH O2S B1S2 0.82V AFS B1 S1 3.25V SHORT FT #1 1.5% LONG FT #1 5.4% TOTAL FT #1 1.08 E D VVT CTRL B1 OFF INJECTOR 8.3ms IGN ADVANCE 5.0deg CALC LOAD 0% MAF 0.00gm/s ENGINE SPD 0rpm COOLANT TEMP186.8F INTAKE AIR 129.2F THROTTLE POS 14% CTP SW ON VEHICLE SPEED0MPH O2S B1S2 0.33V AFS B1 S1 3.29V SHORT FT #1 -0.1% LONG FT #1 5.4% TOTAL FT #1 1.08 VVT CTRL B1 ON 4. Using the right arrow key, toggle the VVTi actuator “ON.” 5. If at this point the vehicle does not run rough and/or stalls when the active test is performed, proceed with Repair Manual P1349 VVTi Fault Isolation Procedure (FIP). If the vehicle does stall and/or runs rough, this indicates the the VVTi control system is operating. Proceed to replace the VVTi actuator following the repair procedures listed on the Technical Information System (TIS): Engine Mechanical Section, Camshaft, Replacement The camshaft timing gear should come in the unlocked position from the factory. If it is difficult to install the camshaft timing gear, the lock pin may be engaged. To disengage the lock pin, apply and hold approximately 20 psi of air pressure at the oil feed hole located 90 degrees clockwise of the oval slot. (See Figure 1.) Once the pin has released, turn the interior assembly counterclockwise. (See black arrow in Figure 1.) B. Put the camshaft timing gear assembly and the camshaft together with the straight pin off the key groove. C. Turn the camshaft timing gear assembly (as shown in Figure 2) while pushing it lightly against the camshaft. Push further at the position where the pin fits into the groove. NOTE: Be sure not to turn the camshaft timing gear to the retard angle side (in the clockwise direction). D. Check that there is no clearance between the end of the camshaft and the camshaft timing gear. E. Tighten the camshaft bolt with the camshaft timing gear fixed. Torque: 54 Nm (551 kgfcm, 40 ftlbf) F. Check that the camshaft timing gear assembly can move to either side and is not locked

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1997 Saturn SL2 FRONT COVER And TIMING CHAIN REMOVAL AND INSTALLATION MANUAL

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Filed Under (Saturn Manuals) by admin on 10-05-2012

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Removal 1. Disconnect negative battery cable. Raise and support vehicle. Drain engine oil. Remove right front wheel and splash shield. Put a block of wood between cradle and engine torque strut at bottom front end of engine. See Fig. 2 . 2. Remove mount from upper front end of engine, allowing engine to rest on wood block. Remove accessory drive belt and tensioner. Remove accessory belt idler. Remove cylinder head cover. 3. Replace silicone isolators on cylinder head cover screws if deteriorated. Remove power steering pump (leave hoses attached). Remove A/C compressor (leave hoses attached). Raise and support vehicle. Drain engine oil. Remove right front wheel and splash shield. 4. Remove support bracket between intake manifold and engine block. Remove front balancer/pulley using a 3-jaw puller. Disconnect exhaust pipe from exhaust manifold. Install Crankshaft Gear Retainer (SA9104E) onto end of crankshaft, with flat side toward crankshaft gear (sprocket). Crankshaft gear retainer holds crankshaft gear in place during removal of front cover. 5. Remove 4 bolts from front end of oil pan. Using RTV Cutter (SA9123E), cut RTV sealant between oil pan and front cover. Spray penetrating oil onto front cover dowel pins. Remove front cover bolts (one bolt is located above accessory drive belt pulley). Pry front cover from engine block. 6. To prevent pistons from hitting valves, turn crankshaft 90 degrees clockwise as viewed from front of engine until timing mark and keyway are aligned with split line of main bearing cap. Remove timing chain tensioner, guides and chain. While using a 7/8″ (21 mm) wrench to keep camshaft(s) from turning, remove camshaft sprocket bolt(s). Remove camshaft sprocket(s). Installation 1. To prevent pistons from hitting valves, ensure timing mark and keyway on crankshaft are aligned with split line of main bearing cap. Install camshaft sprocket(s) with the letters FRT (front) facing away from cylinder head. Use a 7/8″ (21 mm) wrench to keep camshaft(s) from turning. 2. Install and tighten camshaft sprocket bolt(s) to specification. Rotate camshaft(s) until a 3/16″ (4.8 mm) drill bit can be inserted through timing pin hole(s) and into cylinder head. See Fig. 5 or Fig. 6 . 3. Rotate crankshaft counterclockwise as viewed from front of engine until timing marks at crankshaft sprocket are aligned. Install timing chain, aligning Silver-plated chain links with timing mark(s) on camshaft sprocket(s) and bottom tooth (or teeth) of crankshaft sprocket. See Fig. 5 or Fig. 6 . 4. Install fixed chain guide. Slack part of chain should be on tensioner side of cylinder block. Chain should be tight against fixed chain guide. Install pivoting chain guide. Retract tensioner plunger, and pin ratchet

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Ford V8 Engines Performer RPM Hydraulic Roller Camshaft INSTALLATION INSTRUCTIONS

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Filed Under (Ford Manuals) by admin on 01-01-2012

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Disconnect the battery. 2. Drain radiator coolant. Drain plug will normally be located on lower right or left side of the radiator facing the engine. 3. Remove radiator and air conditioning condenser if so equipped. In some cases, the front grill may have to be removed. Measure distance from front cover to grill or brackets that may interfere with camshaft against the length of the camshaft. 4. Remove the gas cap to relieve pressure. Disconnect fuel line and plug. Replace gas cap. 5. Disconnect all linkage from carburetor such as throttle, throttle springs, transmission, cruise control and automatic choke. 6. Tag and remove coil wires and sensor wires. 7. Tag and remove vacuum lines. 8. Remove valve covers. 9. Remove distributor cap and wires, rotate engine until rotor points towards number 1 terminal in cap and pointer on front cover is on top dead center (TDC) and remove distributor. (see Fig. 1) Note: Mark the approximate position of the distributor housing in relation to the manifold to assist in getting the distributor properly located during re-installation. 10. Remove carburetor and intake manifold. Remove and discard intake manifold gasket. 11. Remove rocker arms and pushrods. CAUTION: If your engine has non-adjustable rocker arms (1969-1/2 or later), you must install screw-in studs and high performance •VALVE SPRINGS CAUTION: WARNINGS ABOUT YOUR WARRANTY In order for this Performer RPM roller cam to be covered under ANY WARRANTY, you MUST use the correct Valve Springs. Failure to install the correct valve springs may cause lifters not to follow the cam lobes and damage engine parts. This camshaft is designed to function with valve springs that have a closed pressure of 110 lbs, open pressure of 320 lbs and a lift of .575″. Special H.P. retainers may be necessary with your installation for proper spring height. Do not use rotator type valve springs or retainers for this application. Note: Edelbrock Sure Seat Valve Springs #5762 are not recommended.  IMPORTANT NOTES AFFECTING YOUR WARRANTY CAM LOBE DAMAGE – Cam lobe wear is almost non-existent unless mismatched parts are used or installation of the cam and lifters is done improperly. Cam damage can result from the timing gear loosening due to improper torque on bolts. Bolts holding gear to camshaft should be torqued carefully and a locking compound applied to threads of bolts. Before installing your new Performer-RPM roller camshaft, check the gear drive on the distributor and oil pump for any signs of wear. If worn, be sure to replace with a new gear or you may wear out your camshaft prematurely. High-pressure oil pumps are not recommended with Performer RPM roller camshafts. Edelbrock camshafts are designed to use with Edelbrock timing chains.  CAM GEARS AND CAMSHAFT END PLAY- If cam gear becomes loose, the cam will slide back in the block, causing the lifters to hit the lobes next to them and also the cam bearing journals. If the engine is run after this happens, the bottom of the lifters and the sides of the lobes will become damaged. See Installation Instructions section for end play specifications.  LIFTERS Edelbrock offers a retrofit roller lifter kit for engines not originally equipped with roller lifters. Use part #97453. To install your roller lifters, use fresh clean oil on the lifter and the lifter bore just prior to installing. The guide bar (high side of tappet) must face the opposite side of block. See roller lifter instructions for additional information. ( Note: 289-302 engines require removal of the cylinder heads to provide enough clearance to install roller lifters, which are taller than standard hydraulic lifters.)  PUSHRODS AND ROCKER ARMS High performance pushrods, roller rocker arms and rocker studs are recommended for this installation. After the cam is installed and timed correctly (see Figure 2), it will be necessary to check each pushrod for correct lifter preload. INSTALLATION INSTRUCTIONS 1. Check lifters as covered in Lifters section. Coat cam lobes with fresh clean oil. Lube distributor drive of cam with assembly lube (supplied). 2. Install new camshaft. Re-install thrust plate with new sprockets and timing chain with timing marks lined up as recommended by factory specifications (See Figure 2). Reinstall the fuel pump eccentric before installing sprocket bolt and washer

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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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Ford V6 And V8 Timing Set Installation Instructions

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Filed Under (Ford Manuals) by admin on 23-05-2012

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Installation Instructions 1. Clean everything! Make sure that the engine mounting surfaces and your new timing set have been thoroughly cleaned with a good solvent. 2. If you are using a timing set with three keyways, select the appropriate keyway for your camshaft timing specifications. COMP Cams ® recommends the standard timing position for most applications. This position uses the round or “O” timing and keyway marks. Standard Timing Location: This is the same as original O.E.M. setting. Use keyway and crankshaft gear tooth marked “O”. É 4 Degree Advance: Use keyway and crankshaft tooth marked . Note: The or advanced position should not be used without degreeing the camshaft. Many camshafts have the proper advance built in. Advancing the cam will reduce intake valve to piston clearance and increase exhaust piston to valve clearance. É 4 Degree Retard: Use keyway and crankshaft gear tooth marked . Note: The or retarded position should not be used without degreeing the camshaft. Many cams have the proper advance built in. Retarding the cam will reduce exhaust valve to piston clearance and increase intake piston to valve clearance. 3. Install your lower timing gear on the crankshaft making sure that the timing marks are facing out toward you. 4. Now that the lower timing gear has been installed check the timing mark alignment in your engine manual. Rotate the crankshaft using your crankshaft socket until the timing mark on the gear is in the proper position (12 o’clock). For 240-300 6 cyl. see Note 1 before proceeding! 5. If your engine is equipped with a camshaft retaining plate or thrust plate, it should be installed at this time. Note that many Ford thrust plates are marked “back – bottom”. Before final installation check to make sure that the thrust plate is fitted correctly. 351W owners see Note 2 before proceeding! 6. Temporarily install your camshaft timing gear and rotate the camshaft until the timing mark on the camshaft gear is in the proper position per your engine manual instructions (6 o’clock) Ford Timing Set Installation Instructions

1994 Mitsubishi Expo LRV TIMING BELT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Mitsubishi Manuals) by admin on 30-04-2012

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Removal 1. Remove radiator shroud, cooling fan and pulley. Remove all drive belts and crankshaft pulleys. Remove upper timing belt covers and gaskets. Note bolt length and location. 2. Remove crankshaft sprocket bolt and washer. Rotate crankshaft clockwise (as viewed from timing belt end of engine) until cylinder No. 1 is at TDC of compression stroke. Align timing mark on camshaft sprocket with mark on cylinder head. See Fig. 5 . 3. Loosen timing belt tensioner adjustment bolt, and move tensioner toward water pump. Tighten bolt to secure tensioner. Remove front timing belt and tensioner. DO NOT rotate crankshaft after timing belt has been removed. 4. Remove camshaft sprocket (if necessary). Remove oil pump sprocket access plug from cylinder block. See Fig. 4 . Insert a .31″ (8.0 mm) diameter Phillips screwdriver to block left silent shaft. 5. Remove oil pump sprocket nut, and remove sprocket. Remove front crankshaft sprocket and flange. Note direction and order of installation for reassembly reference. 6. Remove rear timing belt tensioner assembly. Remove rear timing belt. Remove right silent shaft sprocket with spacer (if necessary). Remove rear crankshaft sprocket with key Installation 1. Install rear crankshaft sprocket and flange. Install right silent shaft sprocket and spacer. Spacer should be installed with chamfered end into oil seal. Align timing marks. See Fig. 5 . 2. Install rear tensioner. Hold tensioner tightly against belt while tightening bolts. Ensure deflection is .20- .28″ (5.0-7.1 mm). See Fig. 6 . Install camshaft sprocket. Tighten camshaft sprocket bolt to specification. See TORQUE SPECIFICATIONS . 3. Install front timing belt tensioner, tension spring and spacer. Ensure spring is properly engaged against water pump case. Rotate tensioner toward water pump, and temporarily tighten bolts. Ensure timing marks are aligned. See Fig. 5 . Install timing belt on crankshaft. 4. Apply pressure on tension side of timing belt while installing belt (in order) on crankshaft, oil pump and camshaft sprockets. Loosen tensioner to apply spring pressure to timing belt. 5. To apply tension to belt, rotate crankshaft clockwise until camshaft sprocket timing mark is offset by 2 teeth. Tighten tensioner bolt. Tighten tensioner spacer nut

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1997 Ford Truck F 150 2WD Engine/ Timing Chain/ Cooling and Exhaust Installation Manual

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Filed Under (Ford Manuals) by admin on 31-01-2012

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installation Notes NOTE: Ford does not provide a procedure to align the timing components without the OE tools specified. 1. Compress the tensioner plunger, using an edge of a vise. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result. Do not compress the ratchet assembly. This will damage the ratchet assembly. 2. Use a small screwdriver or pick to push back and hold the ratchet mechanism 3. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing. 4. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation. 5. Remove the tensioner from the vise. 7. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks. 8. Loosely install the Camshaft Holding Tools on both camshafts 9. Install the timing chain guides . 10. Rotate the LH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 12 o’clock. Rotate the RH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 11 o’clock. Tighten the Camshaft 11. Position the crankshaft with the Crankshaft Holding Tool. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur. Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston and/or valve damage can occur. 12. Remove the Crankshaft Holding Tool. Zoom Sized for Print Zoom Sized for Print Fig. 26 Crankshaft Sprocket Position

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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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2002 Land Rover Freelander (LN) Camshaft Timing Belt Service Repair

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Filed Under (Land Rover Manuals) by admin on 09-01-2012

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Service Repair No – 12.65.18 Remove 1. Disconnect battery earth lead. 2. Remove ancillary drive belt . 3. Remove RH front road wheel. 4. Remove 3 bolts securing RH splash shield to body and remove shield. 5. Remove 3 bolts securing camshaft timing belt LH rear cover and remove cover. 6. Rotate crankshaft in a clockwise direction and align the engine “SAFE” position, notch on crankshaft pulley aligned to the “ARROW” on front mounting plate and the timing marks aligned on the rear camshaft gears as illustrated 7. Remove bolt securing PAS pipe to engine front mounting plate. 8. Remove 3 Torx screws securing PAS pump pulley and remove pulley. Zoom Sized for Print Zoom Sized for Print Zoom Sized for Print 9. Remove 3 bolts securing PAS pump to front mounting plate and tie pump aside. 10. Release alternator battery lead terminal cover, loosen terminal nut and disconnect lead from terminal. 11. Disconnect multiplug from alternator. 12. Remove lower bolt and upper nut and bolt securing alternator to front mounting plate. 13. Remove alternator. 14. Remove Torx screw securing idler pulley to front mounting plate and remove pulley 15. Loosen bolt securing lower engine steady to front subframe. 16. Remove bolt securing lower engine steady to sump mounting, release lower engine steady from sump mounting. 17. Remove 3 bolts securing camshaft timing belt RH front cover and remove cover 18. Remove 3 bolts securing camshaft timing belt LH front cover and remove cover. 19. Assemble LRT-12-161 to LRT-12-199 and secure with clamp bolt. 20. Insert LRT-12-161 with LRT-12-199 into crankshaft pulley, loosen and remove pulley bolt. 21. Remove special tool from crankshaft pulley and remove crankshaft pulley. 22. Remove 3 bolts securing camshaft timing belt lower cover to cylinder block and remove cover. 23. Remove 2 bolts securing ancillary drive belt tensioner and remove tensioner. 24. Note fitted position of heat shield on A/C compressor and remove 3 bolts securing A/C compressor to front mounting plate and cylinder block. Release A/C compressor and heat shield and position aside. 25. Drain engine oil.

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