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

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BACKGROUND The current routing of the engine drive belt creates extra force on the drive belt auto-tensioner. In rare cases, this extra force could break the auto-tensioner pivot bolt, causing an engine noise or a loss of power steering. CORRECTIVE ACTION Replace the auto-tensioner pivot bolt, and reroute the drive belt. On vehicles with A/C, install a new drive belt. REPAIR PROCEDURE 1. From above the engine, set a long-handled, boxed- end wrench on the drive belt auto-tensioner. Slowly turn the wrench counterclockwise, then remove the drive belt. NOTE: On vehicles without A/C, the drive belt will be reused. 2. Insert a pulley holder (see REQUIRED SPECIAL TOOLS) into one of the holes in the water pump pulley at the 12 o’clock position. The tool holds the pulley so you can loosen or tighten the pulley bolts. WATER PUMP PULLEY 3. Remove the water pump pulley (three bolts). 4. Remove the pivot bolt from the drive belt auto- tensioner. NOTE: In rare cases, the pivot bolt may be broken. If this has happened, remove the auto-tensioner, then remove the shank of the pivot bolt with Vise Grips or by drilling it out. Do not try to repair the engine block using a TIME-SERT. If you can’t remove the shank of the pivot bolt, you would need DPSM approval to install an engine short block assembly.

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1. Remove the right-hand bank primary timing chain. See: Right-Hand 2. Remove the VVT solenoid. 3. Remove the VVT bush carrier. 4. Install the camshaft locking tool 303-530 to the left-hand bank camshafts, aligning the shafts as necessary. 5. Loosen the exhaust camshaft sprocket bolt. 6. Loosen the intake camshaft VVT unit bolt. 7. Remove the primary chain tensioner bolts. 8. Remove the tensioner assembly. 1. Remove the tensioner. 2. Remove the tensioner back-plate. 9. Remove the chain tensioner blade. 1. Remove the tensioner blade pivot bolt. 2. Remove the tensioner blade. 10. Remove the left-hand bank timing chain. Installation 1. Install the chain tensioning tool 303-532 to the exhaust camshaft sprocket. Reposition the sprocket (and the VVT unit) for the most advantageous position for use of the tool. Remove the tool. 2. Install the primary timing chain. 1. Install the primary chain over the crankshaft sprocket and the VVT unit sprocket. There must be no slack on the drive side of the primary chain and the VVT unit must not be rotated on the camshaft.

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WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WERE (B+ WIRE) FROM GENERATOR. FAILURE TO DO S0 CAN RESULT IN INJURY OR DAMAGE TO ELECTRICAL SYSTEM. 1. Disconnect negative battery cable at battery. 2. Remove generator drive belt. 3. Left Hand Drive (LHD) Vehicles Only: Remove generator pivot and mounting bolts/nut. Position generator for access to wire connectors. 2000 Jeep Truck Cherokee 2WD L6-4.0L VIN S 4. Right Hand Drive (RHD) Vehicles Only:Remove upper nut (generator adjustment nut) and both belt adjustment bolts. Remove generator lower nut/bolt. Position generator for access to wire connectors. 5. If equipped, unsnap plastic cover from B+ terminal. 6. Remove B+ terminal mounting nut at rear of generator.Disconnect terminal from generator. 7. Disconnect field wire connector at rear of generator by pushing on connector tab. 8. Remove generator from vehicle. INSTALLATION 1. Position generator to engine and snap field wire connector into rear of generator. 2. Install B+ terminal to generator mounting stud. Tighten mounting nut to 8.5 Nm (75 in. lbs.) torque. 3. If equipped, snap plastic cover to B+ terminal. 4. LHD Vehicles: Install generator fasteners and tighten as follows: – Generator upper mounting bolt-55 Nm (41 ft. lbs.) torque. – Generator lower pivot bolt/nut-55 Nm (41 ft. lbs.) torque. CAUTION: – Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged. – When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump will be rotating in the wrong direction if the belt is installed incorrectly, causing the engine to overheat. Refer to belt routing label in engine compartment.

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Fig. 1: Exploded View Of Accessory Mount Components Fig. 2: Exploded View Of Timing Belt & Components Fig. 3: Aligning Timing Marks
Fig. 4: Positioning Crankshaft For Timing Belt Installation Fig. 5: Securing Timing Belt With Spring Clips Fig. 6: Adjusting Timing Belt Tension Fig. 7: Measuring Push Rod Protrusion Automatic Tensioner Bolt Camshaft Sprocket Bolt Crankshaft Pulley Center Bolt
Power Steering Pump Bolt Timing Belt Tensioner Arm Pivot Bolt Timing Belt Tensioner Pulley Bolt Coolant Air Bleed Bolt Cooling Fan-To-Pulley Bolt Crankshaft Position Sensor Radiator Mounting Bolt/Nut Timing Belt Cover Bolt

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1. Remove No. 1 spark plug. Using dial indicator, set number one cylinder to TDC of compression stroke. Remove access plug from top of timing belt cover. See Fig. 1 . Ensure timing mark on camshaft aligns with mark on rear cover. See Fig. 2 . 2. Disconnect negative battery cable. Remove accessory drive belts. Raise vehicle and remove right inner splash shield. See Fig. 3 . Remove crankshaft damper bolt. Use gear puller to remove crankshaft damper. 3. Lower vehicle and place a jack under engine to support weight. Remove right engine mount. On Breeze and Stratus, remove generator (with wiring attached) and bracket, and secure out of way. On Neon, remove power steering pump with hoses attached, and secure out of way. On all models, remove right engine mount bracket from engine. See Fig. 4 . 4. Remove front timing belt cover. See Fig. 1 . Rotate crankshaft so that timing marks are aligned. See Fig. 2 . Loosen timing belt tensioner bolts. If reusing timing belt, mark arrow on belt to indicate direction of rotation. Remove timing belt and tensioner. DO NOT loosen, tighten, or remove tensioner pulley pivot bolt. Fig. 1: Exploded View Of Timing Belt & Components