Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-00. 2. Remove the cooling fan and the cooling fan shroud. For additional information, refer to Section 303-03. 3. Remove the accessory drive belt. For additional information, refer to Section 303-01A. 4. Remove the parts in the order indicated in the following illustration and table. 5. To install, reverse the removal procedure. 6. To install, reverse the removal procedure. Item 1: Crankshaft Pulley Bolt Removal Note 1. Remove the bolts and position the power steering cooler aside. 2. CAUTION: This bolt is torque-to-yield and cannot be reused. Using the special tool to hold the crankshaft pulley, remove and discard the damper bolt. Item 2: Crankshaft Pulley Removal Note 1. Using the special tools and two 8 mm (0.31 in) x 1.25 x 100 mm bolts, remove the crankshaft pulley. Item 3: Front Crankshaft Seal Removal Note 1. Using the special tool, remove the crankshaft front seal. Item 3: Front Crankshaft Seal Installation Note 1. Using the special tool, install the crankshaft front seal. Item 2: Crankshaft Pulley Installation Note

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Removal 1. Remove the supercharger drive belt. 2. Remove the fan blade, clutch and shroud. 3. Raise the vehicle on a hoist. 4. Remove the nut and position the shield aside. 5. Remove the transmission cooler line clip. 6. Remove the two nuts and one bolt. 7. Remove the starter motor. 8. Install the special tool. 9. Remove the accessory drive belt. 10. NOTE: The auxiliary supercharger pulley has left-hand threads. Remove the pulley and brace assembly. 11. Remove the supercharger pulley adapter. 12. Remove the bolt. 13. Using the special tool, remove the crankshaft pulley. Installation 1. NOTE: The crankshaft pulley must be installed within four minutes after applying the silicone. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley. 2. Using the special tool, install the crankshaft pulley. 3. Install the bolt and washer. Tighten the bolt in four stages. Stage 1: Tighten to 90 Nm (66 ft. lbs.) . Stage 2: Loosen the bolt. Stage 3: Tighten to 50 Nm (37 ft. lbs.) . Stage 4: Tighten an additional 85 – 90° . 4. Install the supercharger pulley adapter. 5. Install the drive belt. 6. NOTE: Coat the threads of the supercharger pulley with anti-seize lubricant. NOTE: The auxiliary supercharger pulley has left-hand threads. Install the pulley and brace assembly. 7. Remove the special tool. 8. Install the starter motor. 9. Position the transcooler line clip and install the two nuts and one bolt. 10. 11. 12. 13. Position the shield and install the nut. Lower the vehicle. Install the fan blade, clutch and shroud. Install the accessory drive belt and the supercharger drive belt.

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Material 1. 2. 3. 4. With the vehicle in NEUTRAL, position it on a hoist. Remove the fan shroud. Remove the accessory drive belt. Remove the parts in the order indicated in the illustration and table.5. To install. reverse the removal procedure. 6. To install, reverse the removal procedure. Item 1: Crankshaft Pulley Bolt Removal Note 1. Remove the bolts and position the power steering cooler aside. 2. CAUTION: This bolt is torque-to-yield and cannot be reused. Using the special tool to hold the crankshaft pulley. remove and discard the damper bolt. Item 2: Crankshaft Pulley Removal Note 1. Using the special tool and two 8 mm (0.31 inch) x 1.25 x 100 mm bolts, remove the crankshaft pulley. Item 3: Front Crankshaft Seal Removal Note 1. Using the special tool, remove the crankshaft front seal. Item 3: Front Crankshaft Seal Installation Note 1. Using the special tool, install the crankshaft front seal.

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Remove components Caution! Remove the ignition key from the ignition switch before beginning Note! work. Crankshaft or camshaft must not be rotated under any circumstances more than is listed below. Failure to follow these instructions may cause damage to the valves. upper timing belt cover. servo reservoir and expansion tank. Lift up and place on top of engine. Note! Take care not to spill servo oil from the bleed hole in the cap. Place paper wipe around the reservoir and then cover with a plastic bag as protection. Spilled servo oil is highly inflammable. auxiliaries belt. front camshaft belt cover. Position engine according to marking Raise the car. Remove right front wheel. Remove the nut for the cover in the fender liner. Install the upper camshaft belt cover. Turn crankshaft clockwise until the markings on the crankshaft and camshaft pulley correspond. Turn the crankshaft a further 1/4 turn clockwise and then back again until the markings correspond. The markings are illustrated. Remove upper camshaft belt cover.

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Installation Installation 1. Check tensioner pulley for smooth operation. 2. Check tensioner body for leakage or damage. 3. Push pushrod of automatic tensioner unit against a firm surface using a force of 10-20 kg. Pushrod should move less than 1,0 mm. 4. If necessary: Replace automatic tensioner unit. 5. Slowly compress pushrod into tensioner body until holes aligned [11] . Use suitable press or vice. NOTE: Use a suitable washer to protect tensioner body end screw when using press [15] . 6. Retain pushrod with 1,4 mm diameter pin. 7. Install automatic tensioner unit [10] . Tighten bolts [9] . Tightening torque: 24 Nm. 8. Ensure timing marks aligned [6] & [7] . 9. Fit timing belt in anti-clockwise direction, starting at crankshaft sprocket. 10. Ensure belt is taut between sprockets on non-tensioned side. NOTE: Observe direction of rotation marks on belt. 11. Push tensioner pulley by hand against belt. Lightly tighten bolt [8] . 12. Turn crankshaft 1/4 turn anti-clockwise. Use tool No.MD998716. 13. Turn crankshaft 1/4 turn clockwise. Use tool No.MD998716.