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2000 Dodge Intrepid Timing Chain Service and Repair Manual

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Filed Under (Dodge Manuals) by admin on 21-11-2011

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REMOVAL 1.Remove upper intake manifold. 2.Remove cylinder head covers, crankshaft damper, and timing chain cover. CAUTION: When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage. Fig. 70 3.Align crankshaft sprocket timing mark to mark on oil pump housing (Fig. 70). The mark on oil pump housing is 60° ATDC of #1 cylinder. CAUTION: When the timing chain is removed and the cylinder heads are still installed, DO NOT rotate the camshafts or crankshaft without first locating the proper crankshaft position. Failure to do so will result in valve and/or piston damage Fig. 74 4.Remove primary timing chain tensioner from right cylinder head (Fig. 74). 5.Remove camshaft position sensor from left cylinder head (Fig. 69). 6.Remove chain guide access plug from left cylinder head (Fig. 69). NOTE: When camshaft sprocket bolts are removed, the camshafts will rotate in a clockwise direction. 7.Starting with the right camshaft sprocket, remove the sprocket attaching bolts. Remove camshaft damper and sprocket (Fig. 69). 8.Remove left side camshaft sprocket attaching bolts and remove sprocket (Fig. 69). 9.Remove lower chain guide and tensioner arm (Fig. 69). 10.Remove the primary timing chain. INSTALLATION 1.Inspect all sprockets and chain guides. Replace if worn. Refer to Crankshaft Gear/Sprocket, for removal and installation procedures. 2.If removed, install right and left side short chain guides (Fig. 69). Tighten attaching bolts to 28 Nm (250 in. lbs.) 3.Align crankshaft sprocket timing mark to the mark on oil pump housing (Fig. 71). NOTE: Lubricate timing chain and guides with engine oil before installation. 4.Place left side primary chain sprocket onto the chain so that the timing mark is located in-between the two (plated) timing links (Fig. 71). 5.Lower the primary chain with left side sprocket through the left cylinder head opening

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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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CHAIN SUB-ASSEMBLY (2AZ-FE) REMOVAL AND INSTALLATION MANUAL

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Filed Under (More Manuals) by admin on 17-05-2012

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INSTALL CHAIN TENSIONER SLIPPER a. Install the chain tensioner slipper with the bolt. Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.) Zoom Sized for Print 36. INSTALL TIMING CHAIN GUIDE a. Install the timing chain guide with the bolt. Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.) Zoom Sized for Print 37. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 a. Install the sensor plate with the “F” mark facing forward. 38. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL a. Apply multipurpose grease to a new oil seal lip. NOTICE: Keep the lip free of foreign objects. Zoom Sized for Print b. Using SST and a hammer, tap in the new oil seal until its surface is flush with the timing chain cover edge. SST 09223-22010 39. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY a. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block. Zoom Sized for Print b. Apply a continuous bead of seal packing (Diameter 2.0 mm (0.079 inch) ) as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent Zoom Sized for Print NOTICE: • Remove any oil from the contact surface. • Install the chain cover within 3 minutes of applying seal packing. • Do not put in engine oil for at least 2 hours after installing the chain cover. c. Apply a continuous bead of seal packing as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTICE: • Remove any oil from the contact surface. • Install the chain cover within 3 minutes of applying seal packing. • Do not put in engine oil for at least 2 hours after installing the chain cover. Zoom Sized for Print d. Install the timing chain cover with the 14 bolts and 2 nuts. Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.) for bolt A 25 Nm (255 kgf-cm, 18 ft. lbs.) for bolt B 55 Nm (561 kgf-cm, 41 ft. lbs.) for bolt C 43 Nm (438 kgf-cm, 32 ft. lbs.) for bolt D 11 Nm (112 kgf-cm, 8 ft. lbs.) for nut

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2001 Daewoo Leganza SE TIMING BELT REMOVAL And INSTALLATION Manual

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Filed Under (Daewoo Manuals) by admin on 13-05-2011

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TIMING BELT Removal 1. Disconnect negative battery cable. Disconnect intake air temperature sensor connector from intake air duct. Disconnect the air intake tube from the throttle body. Disconnect the breather tube from the valve cover. Remove resonator from throttle body. Remove air filter housing. 2. Raise and support the vehicle. Remove right front wheel. Remove right front splash shield from wheelwell. Remove serpentine accessory drive belt. 3. Remove crankshaft pulley bolts. It is NOT necessary to remove crankshaft sprocket center bolt. Remove crankshaft pulley. Lower vehicle. 4. Support engine assembly from above with Support Fixture (J-28467-B). See Fig. 1 . Remove engine mount bracket from timing belt end of engine. See Fig. 2 . 5. Remove power steering hose clamp bolt, and position hose away from timing belt cover. Remove front timing belt cover. See Fig. 3 . Using crankshaft center bolt, rotate crankshaft one full turn clockwise (as viewed from timing belt end of engine). 6. Align mark on crankshaft sprocket with notch at bottom of rear timing belt cover. See Fig. 4 . Align camshaft sprocket timing marks with notches on valve cover. See Fig. 5 . 7. Loosen the automatic tensioner bolt. Use an Allen wrench to rotate tensioner and relieve tension on timing belt. See Fig. 6 . Remove timing belt Fig. 6: Identifying Timing Belt Tensioner Courtesy of DAEWOO MOTOR AMERICA, INC. Installation 1. Ensure crankshaft and camshaft timing marks are still aligned. Install the timing belt. See Fig. 7 . Turn the timing belt tensioner counterclockwise to tension the timing belt. Turn tensioner until the pointer aligns with the notch on the rear timing belt cover. Tighten automatic tensioner bolt to specification. See TORQUE SPECIFICATIONS . 2. Using crankshaft center bolt, turn crankshaft clockwise (as viewed from timing belt end of engine) 2 full revolutions. Ensure timing belt tensioner pointer is still aligned with notch. 3. If timing belt tensioner is correctly aligned, install timing belt cover. See Fig. 3 . Install the engine mount bracket on the timing belt end of engine. Position power steering hose in place, and install clamp bolt. Install crankshaft pulley. Install serpentine accessory drive belt. 4. Install right front splash shield. Install right front wheel. Install air filter housing and resonator.

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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

TIMING BELT COMPONENTS FOR REMOVAL AND INSTALLATION MANUAL

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Filed Under (More Manuals) by admin on 13-07-2012

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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 Kia Rio L4-1.6L DOHC TIMING BELT Service and Repair Manual

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Filed Under (Kia Motors Manuals) by admin on 28-06-2012

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REMOVAL 1. Disconnect negative battery cable. 2. Loosen power steering lock bolts and nuts accordingly and remove tension from Power Steering (P/S) and/or Air Conditioning (A/C) compressor drive belt . 3. Remove P/S and/or A/C drive belt . 4. Loosen generator mounting bolts and adjusting bolt. 5. Remove generator bolts. 6. Remove water pump pulley. 7. Remove crankshaft pulley and timing belt guide plate. 8. Remove upper and lower timing belt covers. 9. Turn crankshaft so that timing mark on timing belt pulley is aligned with timing mark on engine. 10. Check that “I” mark on intake camshaft pulley is aligned with mark on cylinder head cover and “E” mark on exhaust camshaft pulley is aligned with mark on cylinder head cover. NOTE: Do not move camshaft or crankshaft once timing marks have been correctly positioned. 11. Loosen tensioner pulley lock bolt. 12. Protect timing belt with a rag. 13. Remove tensioner pulley. 14. Remove timing belt. NOTE: Mark the direction of timing belt rotation (on the timing belt) for proper reinstallation. INSPECTION NOTE: Never forcefully twist, turn inside out or bend timing belt. Do not allow oil or grease to come in contact with timing belt. 1. Replace timing belt if it is contaminated with oil or grease

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1996 Mitsubishi Eclipse GS-T TIMING BELT And BALANCE SHAFT BELT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Mitsubishi Manuals) by admin on 29-04-2012

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Removal 1. Disconnect negative battery cable. Remove engine undercover. Place wooden block between jack and oil pan, and raise engine slightly. Remove engine mount assembly near timing belt cover. 2. Remove clamp for power steering return hose near timing belt cover. Remove all drive belts and tensioner pulley bracket. See Fig. 1 . Remove power steering and water pump pulleys. Rotate crankshaft clockwise so that No. 1 cylinder is at TDC of compression stroke. Remove crankshaft pulley. 3. Remove upper timing belt cover and gasket. Remove stub bolt of engine support bracket, and remove center timing belt cover. Remove lower timing belt cover. 4. Ensure camshaft, crankshaft and oil pump sprocket timing marks are aligned. See Fig. 2 or Fig. 3 . Loosen tensioner pulley center bolt. Move tensioner to relieve timing belt tension. Remove timing belt. Remove timing belt auto tensioner. See Fig. 1 . 5. Remove plug from left side of cylinder block. Install a .31″ (8.0 mm) diameter Phillips screwdriver into the hole against balance shaft. See Fig. 4 . Screwdriver must go in at least 2.36″ (60 mm) or more. If screwdriver will only go in about .79-.98″ (20-25 mm) before striking balance shaft, turn sprocket one revolution and align timing mark. Keep screwdriver in place until timing belt is installed. This ensures balance shaft driven by oil pump sprocket remains in correct position. 6. To remove timing belt “B” (balance shaft belt), hold crankshaft sprocket stationary with a spanner wrench. Remove crankshaft sprocket bolt. Using gear puller, remove outer crankshaft sprocket. 7. Remove crankshaft sensing blade (if equipped). See Fig. 5 . Loosen timing belt “B” tensioner bolt. If reusing timing belt “B”, mark direction of belt rotation for reassembly reference. Remove timing belt “B Inspection 1. Inspect timing belts for damaged teeth and cracking. Ensure belts are not contaminated with oil. Check tensioners for free rotation and grease leakage. Replace components if damaged or if grease leakage exists. 2. Check timing belt auto tensioner for leaks. Hold timing belt auto tensioner upright. Measure rod protrusion above edge of housing. See Fig. 6 . Length should be .47″ (12 mm). Apply 22-44 lbs. (10-20 kg) of force to end of rod. If auto tensioner rod moves more than 0.39″ (1 mm), replace the auto tensioner.

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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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2004 Dodge Truck RAM 1500 Truck 2WD TIMING CHAIN AND SPROCKETS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Dodge Manuals) by admin on 10-06-2012

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TIMING CHAIN AND SPROCKETS Precaution: Timing Chain Replacement CHAIN GUIDES AND TENSIONER ARMS: Replace these parts if grooving in plastic face is more than 1 mm (0.039 inch) deep. If plastic face is severely grooved or melted, the tensioner lube jet may be clogged. The tensioner should be replaced. REMOVAL 1. Disconnect negative cable from battery. 2. Drain cooling system . 3. Remove right and left cylinder head covers. 4. Remove radiator fan shroud. 5. Rotate engine until timing mark on crankshaft damper aligns with TDC mark on timing chain cover (Fig. 132) (# 1 cylinder exhaust stroke) and the camshaft sprocket “V8″ marks are at the 12 o’clock position (Fig. 133). 6. Remove power steering pump. 7. Remove access plugs (2) from left and right cylinder heads for access to chain guide fasteners (Fig. 134). 8. Remove the oil fill housing to gain access to the right side tensioner arm fastener. 9. Remove crankshaft damper and timing chain cover. 10. Collapse and pin primary chain tensioner (Fig. 135). CAUTION: Plate behind left secondary chain tensioner could fall into oil pan . Therefore, cover pan opening. 11. Remove secondary chain tensioners. 12. Remove camshaft position sensor from right cylinder head (Fig. 136). CAUTION: Care should be taken not to damage camshaft target wheel. Do not hold target wheel while loosening or tightening camshaft sprocket. Do not place the target wheel near a magnetic source of any kind. A damaged or magnetized target wheel could cause a vehicle no start condition. CAUTION: Do not forcefully rotate the camshafts or crankshaft independently of each other. Damaging intake valve to piston contact will occur. Ensure negative battery cable is disconnected to guard against accidental starter engagement. 13. Remove left and right camshaft sprocket bolts.

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