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TOYOTA AND LEXUS HIGHLANDER HYBRID REMOVAL AND INSTALLATION MANUAL

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Filed Under (Toyota Manuals) by admin on 08-03-2012

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Engine and Vehicle Identification Chart………………………………………..4-2 General Engine Specifications………4-2 Engine Tune-Up Specifications……..4-2 Capacities ………………………………….4-3 Valve Specifications …………………….4-3 Crankshaft and Connecting Rod Specifications……………………..4-3 Camshaft and Bearing Specifications ……………………………4-4 Piston and Ring Specifications……..4-4 Torque Specifications………………….4-4 Wheel Alignment ………………………..4-5 Tire, Wheel and Ball Joint Specifications ……………………………4-5 Brake Specifications ……………………4-5 Scheduled Maintenance Intervals……………………………………4-6 STEERING AND SUSPENSION ………………4-28 A Air Bag…………………………………….4-28 Disarming ……………………………4-28 Precautions ………………………….4-28 Alternator …………………………………..4-7 B Brake Caliper ……………………………4-30 Removal And Installation……….4-30 C Camshaft and Valve Lifters…………4-14 Inspection ……………………………4-16 Removal & Installation…………..4-14 CV-Joints………………………………… 4-24 Overhaul ……………………………..4-24 Cylinder Head …………………………..4-10 Removal & Installation…………..4-10 D Disc Brake Pads………………………..4-32 Removal And Installation……….4-32 E Engine Assembly ………………………..4-7 Removal & Installation…………….4-7 Exhaust Manifold ………………………4-12 Removal & Installation…………..4-12 F Front Crankshaft Seal………………..4-14 Removal & Installation…………..4-14 Front Halfshaft………………………….4-23 Removal & Installation…………..4-23 Front Strut ……………………………….4-28 Removal & Installation…………..4-28 Front Wheel Bearing………………….4-29 Fuel Filter ………………………………..4-21 Fuel Injector……………………………..4-22 Removal & Installation…………..4-22 Fuel Pump ……………………………….4-21 Removal & Installation…………..4-21 Fuel System Pressure………………..4-21 Relieving ……………………………..4-21 H Heater Core………………………………..4-7 Removal & Installation…………….4-7 Hybrid Transaxle Assembly…………4-22 Removal & Installation…………..4-22 I Ignition Timing ………………………….. 4-7 Adjustment…………………………….4-7 Intake Manifold …………………………4-11 Removal & Installation…………..4-11 L Lower Ball Joint………………………..4-29 Removal & Installation…………..4-29 Lower Control Arm……………………4-29 Removal & Installation…………..4-29 O Oil Pan…………………………………….4-18 Removal & Installation…………..4-18 Oil Pump …………………………………4-18 Removal & Installation…………..4-18 P Pinion Seal ………………………………4-27 Removal & Installation…………..4-27 Piston and Ring………………………..4-21 Positioning ………………………….4-21 Power Rack And Pinion Steering Gear…………………………..4-28 Removal & Installation…………..4-28 R Rear Halfshaft………………………….. 4-24 Removal And Installation……….4-24 Rear Main Seal…………………………4-19 Removal & Installation…………..4-19 Rear Strut…………………………………4-28 Conventional Strut Overhaul…..4-28 Removal And Installation……….4-28 Rear Traction Motor…………………..4-22 Removal & Installation…………..4-22 Rear Wheel Bearing…………………..4-29 Removal And Installation……….4-29 T Timing Belt ………………………………4-19 Removal & Installation…………..4-19 V Valve Lash ……………………………….4-17 Adjustment…………………………..4-17 W Water Pump ……………………………..4-10 Removal & Installation………..

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2005 Ford F-150 Drive Pinion Flange and Drive Pinion Seal Repair Manual

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Filed Under (Ford Manuals) by admin on 21-04-2012

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 . 2. Remove the brake disc. For additional information, refer to Section 206-04 . 3. Index-mark the driveshaft flange and pinion flange for correct alignment during installation. 4. Remove the 4 driveshaft flange bolts. 5. NOTE: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft centering socket yoke from the pinion flange. Pry only in the area shown with a suitable tool to disconnect the driveshaft centering socket yoke from the pinion flange. Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the pinion flange. ? Using mechanic’s wire, position the driveshaft aside. 6. Using a Nm (lb-in) torque wrench on the pinion nut, record the torque required to maintain rotation of the pinion gear through several revolutions. 7. Using the special tool to hold the pinion flange, remove and discard the pinion nut.2005 F-150 Workshop Manual 8. Index-mark the pinion flange in relation to the drive pinion stem to make sure of correct alignment during installation. 9. Using the special tool, remove the pinion flange. 10. Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer until the drive pinion seal is removed. Installation 1. Lubricate the new drive pinion seal with grease. 2. Using the special tool, install a new drive pinion seal. 3. Lubricate the pinion flange splines with axle lubricant. 4. NOTE: Disregard the scribe marks if a new pinion flange is being installed. Align the pinion flange with the drive pinion shaft. 5. Using the special tool, install the pinion flange. 6. l a new pinion nut with the same iginal if not replacing the collapsible spacer. If a installed, install the nut in the kit, as indicated in the chart below, or damage to the component may occur. Position the new pinion nut. Pinion Nut 7. no circumstances ut to be backed off to reduce drive pinion bearing preload. If reduced drive pinion bearing preload is required, a new drive pinion collapsible spacer and pinion nut must be installed or damage to the component may occur. NOTE: Remove the special tool while taking drive pinion bearing preload readings with the Nm (lb-in) torque wrench. Using the special tool to hold the pinion flange, tighten the pinion nut. ? Rotate the drive pinion occasionally to make sure the drive pinion bearings are seating correctly. ? Install a Nm (lb-in) torque wrench on the pinion nut. ? Rotating the drive pinion through several revolutions, take frequent drive pinion bearing preload readings until the original recorded drive pinion bearing preload reading is obtained. ? If the original recorded drive pinion bearing preload is lower than specification, tighten to the appropriate specification for used drive pinion bearings. If the drive pinion bearing preload is higher than specification, tighten the pinion nut to the original reading as recorded. For additional information, refer to the Specification portion of this section. 8. Position the driveshaft and align the index mark on the pinion flange.

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Ford 455C 555C 655C Tractor Loader Backhoe Service Manual

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

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Engine Systems Chapter 1 3-Cylinder Diesel Engine 3-Cylinder Diesel Engine – Description and Operation 3-Cylinder Diesel Engine – Overhaul Chapter 2 4-Cylinder Diesel Engine 4-Cylinder Diesel Engine – Description and Operation 4-Cylinder Diesel Engine – Overhaul Chapter 3 Cooling System Cooling System – 3-Cylinder Engine Description and Operation Cooling System – 4-Cylinder Engine Description and Operation Cooling System – Overhaul Chapter 4 Troubleshooting, Specifications and Special Tools Troubleshooting Specifications Special Tools Part 2 Fuel Systems Chapter 1 Fuel System – General Fuel System – Description and Operation Fuel System – Adjustments DPA Distributor Type Fuel Injection Pump Fuel System – Adjustments DPS Distributor Type Fuel Injection Pump Fuel System – Fuel Tanks, Filters and Fuel Lines Overhaul Chapter 2 Fuel Injection Pump – DPA Distributor Type Fuel Injection Pomp – Description and Operation Fuel Injection Pump – Overhaul Fuel Injection Pump – ISO Test Conditions Fuel Injection Pump – Test Procedures Chapter 3 Fuel Injection Pump – DPS Distributor Type Fuel Injection Pump – Description and Operation Fuel Injection Pump – Overhaul Fuel Injection Pump – ISO Test Conditions Fuel Injection Pump – Test Procedure Chapter 4 Injectors Ford 455C Injectors – Description and Operation Injectors – Overhaul Chapter 5 Injectors Ford 555C and 655C Injectors – Description and Operation Injectors – Overhaul Chapter 6 Air Cleaners Dry Type Air Cleaner – Description and Operation Dry Type Air Cleaner – Overhaul Chapter 7 Turbocharger Turbocharger – Description and Operation Turbocharger – Overhaul Chapter 8 Troubleshooting, Specifications, Test Plans and Special Tools Troubleshooting – Diesel Engines Troubleshooting – Turbocharger Specifications Special Tools Test Plans Part 3 Electrical System Chapter 1 Wiring, Lights and Controls Wiring, Lights and Controls – Description and Operation Wiring, Lights and Controls – Fault Finding and Repair Circuit Diagrams and Wiring Harness Chapter 2 Battery
Battery – Description and Operation Battery – Maintenance and Tests Chapter 3 Starting System Starting System – Description and Operation Starting Motor – Overhaul Chapter 4 Charging System – A127 55 Amp Alternator with Integral Regulator Charging System – A127 55 Amp Alternator with Integral Regulator – Description and Operation Charging System – A127 55 Amp Alternator with Integral Regulator – Service Precautions, Preliminary Checks, Initial Tests and Alternator Component Tests Charging System – A127 55 Amp Alternator with Integral Regulator – Overhaul Chapter 5 Troubleshooting, Specifications and Special Tools Troubleshooting Specifications Special Tools Part 4 Power Reversing Transmission Chapter 1 4×4 Fully Synchronized Power Reversing Transmission Power Reversing Transmission – Description and Operation Introduction to Overhauling the Transmission Gear Shift Lever, Modulator Unit and Solenoid Control Valve – Overhaul Front End Overhaul Complete Overhaul Component Overhaul Chapter 2 8X8 Fully Synchronized Power Reversing Transmission Power Reversing Transmission – Description and Operation Introduction to Overhauling the Transmission Gear Shift Lever, Modulator Unit, Lockup Valves and Solenoid Control Valve – Overhaul Front End Overhaul Complete Overhaul Component Overhaul

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ALL INFINITI BRAKE NOISE/ JUDDER/ PEDAL FEEL DIAGNOSIS AND REPAIR MANUAL

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Filed Under (Infiniti Manuals) by admin on 23-04-2012

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SERVICE PROCEDURE 1. Verify the condition by road testing the vehicle with the customer. 2. Determine the specific brake issue based on the description in the Service Information above. 3. Follow the appropriate repair procedure(s), listed on the following pages, for your specific issue BRAKE NOISE • Brakes can make a range of noises when applied or released. Some noises are normal and no repair action should be taken. • Use the following descriptions to identify the specific type of brake noise and the appropriate repair: Squeak noise when the brakes are cold: • Usually occurs during the first few stops in the morning. • This is a normal condition. No service action is necessary Squeak noise with the brakes at normal operating temperatures: • listed under Brake Service on page 5 of this bulletin and the appropriate Service Manual procedures. • Refer to technical bulletins specific to the model of vehicle regarding this issue. If there are no bulletins for the car you are working on, install OE type pads using the information Notes about brake pads and brake noise: Original Equipment (OE) brake pads are installed on all current Infiniti vehicles at the factory. The OE pads use a Non-asbesto • s Organic (NAO) compound. The NAO material provides state of the art resistance to squeal noise. • ervice parts and must be used if replacing brake pads under the terms of • ted under Brake Service on page 5 of this bulletin and the appropriate Service Manual Gro n s after coming to a stop: • It is a normal condition. No repair or service is necessary. Groan noise during stopping: • Usually caused by glazing of the rotor’s surface as a result of heavy or frequent braking. • Refer to technical bulletins specific to the model of vehicle regarding this issue. • Replace the brake pads, then resurface the rotors and finish them with sand paper. Refer to Brake Service on page 5 for additional detail. Single clunk noise from front suspension when applying the brakes: • The noise is a result of the brake pads shifting in the direction of rotor rotation when the brakes are applied. Can be duplicated by lightly touching the brake pedal. • • If the brake pedal is pushed hard, the noise is less likely to occur. Make sure the brake pads and pad hardware (shims, springs, clips, etc) are installed correctly. Refer to ASIST for vehicle specific brake service information. Refer to Brake Service on page 5 for additional detail. Mull e he engine is started: • st er models, the self check occurs the first aches 5 mph after the engine is started. ors or drums. • WARNING: Brake dust may be hazardous if inhaled. Refer to the Service Manual (ESM) for brake • n and lubrication of brake pads, CAUTION: Do not get grease on the brake pad friction surface. A • Brake Judder is caused by rotor thickness variation and/or rotor run out.

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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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2001 Ford Taurus/ Sable Cooling System Draining Filling and Bleeding Workshop Manual

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Filed Under (Ford Manuals) by admin on 19-02-2011

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CAUTION: Vehicle cooling systems are filled with Motorcraft Premium Engine Coolant VC-4-A (in Oregon VC-5, in Canada CXC-10) or an equivalent meeting Ford specification ESE-M97B44-A. NOTE: Less than 80% of the coolant capacity can be recovered with the engine in the vehicle. Dirty, rusty or contaminated coolant requires replacement. 1. Release the pressure in the cooling system by slowly turning the pressure relief cap one half to one turn counterclockwise to the first stop on the filler neck. When the pressure has been released, remove the pressure relief cap. 2. Raise and support the vehicle. For additional information, refer to Section 100-02 . 3. Remove the front splash shield. 4. Place a suitable container below the radiator draincock. Drain the coolant. 5. Close the radiator draincock when finished. Filling and Bleeding With RADKITPLUS 1. Using the special tool, install the RADKITPLUS and follow the RADKITPLUS manufacturer’s instructions to fill and bleed the cooling system. Filling Without RADKITPLUS CAUTION: Engine coolant provides freeze protection, boil protection, cooling efficiency and corrosion protection to the engine and cooling components. In order to obtain these protections, the engine coolant must be maintained at the correct concentration and fluid level. When adding engine coolant, use a 50/50 mixture of engine coolant and clean, drinkable water. To maintain the integrity of the coolant and the cooling system: * Add Motorcraft Premium Engine Coolant VC-4-A (in Oregon VC-5, in Canada CXC-10) or equivalent meeting Ford specification ESE-M97B44-A. * Do not add Motorcraft Specialty Engine Coolant VC-2 or an equivalent meeting Ford specification WSS-M97B44-D. Mixing coolants may degrade the coolant’s corrosion protection. * Do not add alcohol, methanol, brine or any engine coolants mixed with alcohol or methanol antifreeze. These can cause engine damage from overheating or freezing. * Do not mix with recycled coolant unless it meets the requirement of specification ESE-M97B44-A. Not all coolant recycling processes meet this specification. Use of such a coolant may harm the engine and cooling system components. 1. Install the front splash shield. 2. Lower the vehicle. 3. Fill the degas bottle with the correct engine coolant mixture. 4. Install the pressure relief cap. 5. Move the temperature blend selector to the full warm position. 6. WARNING: Do not stand in line with or near the engine cooling fan blade when revving the engine. Run the engine until it reaches operating temperature. 7. Add the correct coolant mixture to the degas bottle until the coolant level is between the COOLANT FILL LEVEL marks. 8. Turn off the engine and allow the cooling system to cool. Recheck the coolant level and fill the cooling system to the FULL mark on the degas bottle. 9. WARNING: Do not stand in line with or near the engine cooling fan blade when revving the engine. Repeat Steps 3 through 8 until the reservoir level is OK. Bleeding Without RADKITPLUS 1. Bleed the cooling system as follows: * Select the maximum heater temperature and blower motor speed settings. Position the control to discharge air from the A/C vents in the instrument panel. * WARNING: Do not stand in line with or near the engine cooling fan blade when revving the engine. Start the engine and allow it to idle. While the engine is idling, feel for hot air from the A/C vents. * CAUTION: If the air discharge remains cool and the engine coolant temperature gauge does not move, the engine coolant level is low in the engine and must be filled. Stop the engine, allow it to cool and fill the cooling system. Start the engine and allow it to idle until the normal operating temperature is reached. Hot air should discharge from the A/C vents. The engine coolant temperature gauge should maintain a stabilized reading in the middle of the NORMAL range and the upper radiator hose should feel hot to the touch. * Shut the engine off and allow it to cool. * Check the engine for coolant leaks. * Check the engine coolant level in the degas bottle and fill it as necessary.

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Toyota Venza Installation Instructions

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Filed Under (Toyota Manuals) by admin on 25-11-2011

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1. If vehicle is AWD- ( A ll- W heel D rive), then see Note & Figure B . above. It is important to the proper operation of the vehicle to reinstall sway bar brackets properly as shown. 2. If vehicle is AWD then remove sway bar brackets both sides, saving existing nuts. 3. Lower exhaust by removing (4) exhaust rubber isolators that support muffler and tailpipe from hangers. 4. Raise hitch into position as shown in Figure A. above and install (3) 10mm bolts and toothed washers per side into vehicle frame weldnuts. If vehicle is AWD then reinstall sway bar bracket with spacer block supplied between lower vehicle attachment and sway bracket as shown in Figure B. both sides, using existing nut for lower attachment. 5. Tighten bolts to proper torque as described below. Raise exhaustand re-attach rubber isolators

Dodge Ram 1500 4wd Installation Instructions

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Filed Under (Dodge Manuals) by admin on 25-12-2011

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Step 1: (A) Position truck on a flat surface and lift vehicle by the frame so that the front wheels are off the ground using a floor jack and jack stands or a (2) two post lift if available. Next locate the torsion key at the rear of the torsion bar under the cab of the truck. (Insert A) Note: Prior to lifting the vehicle it is recommended that you measure the stock height of the vehicle so that you have a base line to gauge when you are adjusting the height of the vehicle. Measuring the vehicle from the bottom of the wheel to the lip of the fender as in (Insert B) is recommended. (B) Step 2: Remove the torsion key adjusting bolt completely. Using a ReadyLift® Torsion Bar Unloading Tool Part # 66-7822A, and the bracket supplied in the kit as shown in (Insert C) Compress the key so that you can remove the threaded part of the torsion adjuster. Releasing the tension on the unloading tool will now release the tension on the torsion bar. Slide torsion bar forward allowing the torsion key to be removed. As in (Insert D) Insert C Insert D Installation Instructions 02-05 Dodge Ram 1500 4wd (cont.) Step 3: Install the Forged torsion key and slide torsion bar back into position as in (Insert E) IMPORTANT! Make sure Torsion Bar is extended at least ¼inch through the Torsion Key. Apply pressure with Torsion Bar Unloading Tool to the torsion key, and create enough space to reinsert the torsion key keeper that the adjusting bolt threads into. Insert E Step 4: Reinstall the adjusting bolt, and adjust it so ¼” of bolt threads extend beyond torsion key keeper. IMPORTANT! – Each ¼” of adjustment on the bolt equals 1″ at the wheel. It is best to check ride height after this initial setting and adjust as needed. Step 5: Repeat steps 1 through 3 on the Passenger Side of the vehicle. Follow each step closely making sure to double check the torque on all fasteners. Measure the distance between the tires and fenders to make sure both sides of the truck are even. Step 6: Wheel Alignment; a Certified Alignment Technician that is experienced with lifted vehicles is recommended to perform the alignment. *It is recommended that you have your vehicle’s alignment checked whenever installing new tires. *It is also recommended that you adjust your headlights whenever your vehicle’s ride height is altered.

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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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