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serpentine belt diagram td4 freelander 1

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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


REPAIR PROCEDURE This repair is compatible with DaimlerChrysler’s Mobile Service Program and does not require hoists or other full service facility special equipment. 1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise ( Fig. 3 ). 2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount. 3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal fastener. DO NOT remove the large nut in the center of the core of the insulator ( Fig. 4 ). 4. Remove the load on the engine mount by carefully supporting the engine with a floor jack. 5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine mount assembly. 6. Remove the idler pulley from the engine mounting bracket. ( Fig. 3 ). 7. Remove the engine mounting bracket. 8. Install a new engine mounting bracket. Torque the fasteners to 40-68 N.m (30-50 ft-lbs.). 9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 N.m (30-50 ft-lbs.). 10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new belt if there is any evidence of damage to the original one). 11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly release the belt tensioner. 12. Install the engine mount; torque the assembly in the following order, engine mount to rail fasteners 68 N.m (50 ft-lbs.), vertical fastener 102 N.m (75 ft-lbs.), and horizontal fastener 150 N.m (111 ft-lbs.). 13. Install the purge duty cycle solenoid to the engine mount. 14. Start the vehicle and let it run for one minute then turn the engine off. 15. Verify the serpentine belt is properly aligned ( Fig. 1 ) 16. If the serpentine belt has moved toward the outboard edge of the idler pulley, further diagnosis will be required. WARRANTY INFORMATION POLICY: Reimbursable within the provisions of the warranty. LABOR OPERATION NO: 07-20-20-96 TIME ALLOWANCE: 0.7 Hrs. FAILURE CODE: P8 – New Par

1999 Volkswagen New Beetle GL timing belt replacement manual

REMOVAL & INSTALLATION NOTE: For 2004, manufacturer does not provide a timing belt replacement interval. CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. NOTE: Engine code AEG is stamped into machined pad on front of cylinder block above crankcase breather, near cylinder head mating surface. See Fig. 1 . For all other 2.0L engines, engine code is stamped on transmission mating flange at the rear of the engine. See Fig. 2 . For all engines, code can also be found on the vehicle data plate and on a sticker on the timing belt cover. Fig. 2: Locating Engine Identification Code (AVH, AZG, BDC & BEV) Courtesy of VOLKSWAGEN UNITED STATES, INC. TIMING BELT Removal (AEG, AVH, AZG, BEV & BDC Engine Codes) 1. Remove right hand insulation tray from engine compartment. Remove engine cover. Rotate serpentine belt tensioner clockwise to relieve belt tension. Remove serpentine belt. See Fig. 3 . Lock in place using Mandrel (T10060) or a drift. Fig. 3: Releasing Serpentine Belt Tensioner Courtesy of VOLKSWAGEN UNITED STATES, INC. 2. Remove serpentine belt tensioner assembly. See Fig. 4 . Turn crankshaft to TDC position. See Fig. 5 . Align TDC marks visible in bellhousing access hole. See Fig. 6 . Remove upper timing belt cover. Ensure camshaft sprocket timing mark aligns with mark on rear cover. See Fig. 5 . 3. Support engine from above or below with floor jack to take engine weight off of mounts. Remove coolant reservoir and set aside. On Golf and Jetta, remove power steering reservoir (hoses attached), and set aside. On New Beetle, pull off EVAP hoses at EVAP canister and throttle valve housing. 4. On all models, remove engine mount from timing belt end of engine. See Fig. 7 . Remove crankshaft pulley from crankshaft sprocket. It is NOT necessary to remove center bolt (center bolt is torque-to-yield type that must be replaced if removed). 5. Remove timing belt covers. Remove engine support from front of engine. See Fig. 4


REMOVAL & INSTALLATION TIMING BELT Removal 1. Disconnect negative battery cable. Remove engine cover. Using 16-mm spanner wrench, rotate serpentine belt tension arm clockwise about 14 degrees to relieve belt tension. Remove serpentine drive belt. Remove power steering pump pulley, idler pulley, tensioner pulley and crankshaft pulley. Remove upper and lower timing belt covers. See Fig. 1 or Fig. 2 . 2. Ensure timing marks of camshaft sprocket and cylinder head cover are matching. See Fig. 5 . On Sedona, support engine with jack and remove engine mounting insulator. On all models, remove auto tensioner. See Fig. 3 . 3. Unbolt timing belt tensioner pulley, and remove timing belt. CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. NOTE: Rotate crankshaft clockwise and align timing mark to set No. 1 cylinder to TDC on compression stroke. NOTE: If timing belt is to be reused, mark rotational direction on belt for reinstallation reference. CAUTION: If either camshaft is set at TDC for cylinder No. 1 at the compression stroke and the corresponding camshaft on the same cylinder head is rotated 180 degrees while the timing belt is removed, intake and exhaust valves may contact each other Inspection Inspect timing belt for wear on edges of drive teeth. Inspect the belt for signs of oil contamination, cracks, separation, worn or missing teeth, or hardened Black surface. Replace belt if worn, damaged or contaminated. Inspect belt tensioner pulley for smooth rotation. Replace if defective. Check timing belt auto tensioner for leaks. Replace if necessary. Installation 1. Install timing belt idler pulley to engine support lower bracket. Install tensioner arm, shaft and washer to cylinder block. Tighten tensioner arm bolt to specification. See TORQUE SPECIFICATIONS . 2. Install crankshaft sprocket and align timing mark. See Fig. 4 . Install camshaft sprocket and adjust installation positions as shown. See Fig. 5 and Fig. 6 . Install auto tensioner to oil pump case. Ensure that

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

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.