REMOVAL & INSTALLATION

Size: px

Start display at page:

Download "REMOVAL & INSTALLATION"

Roxanne Copeland
5 years ago
Views:

1 REMOVAL & INSTALLATION TIMING BELT Removal 1. Disconnect negative battery cable. Rotate engine clockwise and position cylinder No. 1 on TDC of compression stroke. Ensure "O" mark on crankshaft pulley aligns with "O" mark on outer timing belt cover. 2. Looking through plug hole of outer timing belt cover, ensure camshaft sprocket timing mark aligns with cover pointer. See Fig Remove fan guard, cooling shroud, cooling fan and fan shroud. Remove drive belt, water pump pulley and automatic belt tensioner. Discharge A/C system (if equipped) using approved refrigerant recovery equipment. Remove A/C compressor mounting bracket with power steering pump attached, and position aside. Drain cooling system. Remove upper radiator hose. Remove thermostat housing and gasket. 4. Remove retaining bolt and crankshaft pulley. Remove hub assembly retaining bolt from crankshaft. Remove outer timing belt cover. Ensure camshaft sprocket timing mark aligns with cover pointer. See Fig Loosen belt tensioner bolts. Using Camshaft Belt Tensioner (T74P-6254-A) or equivalent, release spring tension on belt tensioner. Rotate belt tensioner away from timing belt and tighten bolts. 6. On distributorless models, remove retaining bolts and pull crankshaft sensor from dowel pins. See Fig. 1. Remove hub assembly. On all models, note direction of belt guide installation, and remove belt guide. Remove timing belt. Tuesday, February 16, :23:07 7:23:10 PM Page Mitchell Repair Information Company, LLC.

2 Fig. 1: Exploded View Of Timing Belt & Components (Typical) Courtesy of FORD MOTOR CO. Installation (Models With Distributor) Tuesday, February 16, :23:07 PM Page Mitchell Repair Information Company, LLC.

3 1. Install crankshaft sprocket (if removed) with recessed area toward crankshaft. See Fig. 1. Install belt guide with flat side toward camshaft sprocket. Install camshaft sprocket with timing mark outward. CAUTION: If camshaft sprocket was removed, install NEW camshaft sprocket bolt. DO NOT reuse bolt. 2. Install NEW camshaft sprocket bolt, and tighten to specification while holding camshaft with camshaft sprocket holder. See TORQUE SPECIFICATIONS. 3. Align camshaft sprocket timing mark with pointer. Properly position crankshaft so timing mark aligns with notch in front cover casting. See Fig. 2. Remove the distributor cap, and ensure that the distributor rotor is facing the No. 1 position. 4. Install timing belt over crankshaft sprocket, then counterclockwise over auxiliary shaft and camshaft sprockets. Loosen belt tensioner bolt, allowing tension to be applied on timing belt. It may be necessary to push belt tensioner against timing belt, as spring tension may not move belt tensioner against timing belt. 5. Remove one spark plug from each cylinder. Rotate engine clockwise (viewed from front of engine) 2 complete revolutions. Tighten timing belt tensioner bolts to specification. See TORQUE SPECIFICATIONS. Ensure all timing marks align properly. See Fig. 1. Install belt guide on crankshaft. 6. To install remaining components, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. 7. Disconnect heater hose from fitting on thermostat housing to bleed air from cooling system when filling. Fill cooling system with Ford Coolant (E2FZ AA), or equivalent, until coolant flows from fitting. Install heater hose. Refill radiator. Adjust drive belts to proper tension. Tuesday, February 16, :23:07 PM Page Mitchell Repair Information Company, LLC.

4 Fig. 2: Positioning Crankshaft Courtesy of FORD MOTOR CO. Installation (Models Without Distributor - Except 1994 Ranger) 1. Install crankshaft sprocket (if removed) with recessed area toward crankshaft. See Fig. 1. Install belt guide with flat side toward camshaft sprocket. Install camshaft sprocket with timing mark outward. CAUTION: If camshaft sprocket was removed, install NEW camshaft sprocket bolt. DO NOT reuse bolt. 2. Install NEW camshaft sprocket bolt, and tighten to specification while holding camshaft with camshaft sprocket holder. See TORQUE SPECIFICATIONS. 3. Align camshaft sprocket timing mark with pointer. Properly position crankshaft so timing mark aligns with notch in front cover casting. See Fig. 2. Tuesday, February 16, :23:07 PM Page Mitchell Repair Information Company, LLC.

5 4. Install timing belt over crankshaft sprocket, then counterclockwise over auxiliary shaft and camshaft sprockets. Loosen belt tensioner bolt, allowing tension to be applied on timing belt. It may be necessary to push belt tensioner against timing belt, as spring tension may not move belt tensioner against timing belt. 5. Remove one spark plug from each cylinder. Rotate engine clockwise (viewed from front of engine) 2 complete revolutions (have an assistant hold crankshaft pulley to prevent rotation). Using torque wrench, turn cam sprocket counterclockwise until torque reads 40 ft. lbs. (54 N.m). Tighten timing belt tensioner bolts to specification. See TORQUE SPECIFICATIONS. Ensure all timing marks align properly. See Fig Install belt guide on crankshaft. Install crankshaft sensor over dowel pins. Tighten long crankshaft sensor bolts to ft. lbs. (19-30 N.m). 7. Rotate crankshaft counterclockwise approximately 45 degrees. Install hub assembly and crankshaft pulley. Tighten bolts to specification. See TORQUE SPECIFICATIONS. 8. Install Crankshaft Sensor Positioner (T89P-6316-A). See Fig. 3. Rotate crankshaft clockwise approximately 90 degrees so outer vane of hub assembly engages with crankshaft sensor positioner. Tighten short crankshaft sensor bolts to ft. lbs. (19-30 N.m). 9. Rotate crankshaft counterclockwise 90 degrees, and remove crankshaft sensor positioner. Rotate crankshaft 90 degrees clockwise, and measure the outer vane-to-sensor air gap. The air gap must be " ( mm). 10. To install remaining components, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. 11. Disconnect heater hose from fitting on thermostat housing to bleed air from cooling system when filling. Fill cooling system with Ford Coolant (E2FZ AA), or equivalent, until coolant flows from fitting. Install heater hose. Refill radiator. Adjust drive belts to proper tension. Tuesday, February 16, :23:07 PM Page Mitchell Repair Information Company, LLC.

6 Fig. 3: Positioning Crankshaft Sensor Courtesy of FORD MOTOR CO. Installation (Models Without Distributor Ranger) 1. Install crankshaft sprocket (if removed) with recessed area toward crankshaft. See Fig. 1. Install belt guide with flat side toward camshaft sprocket. Install camshaft sprocket with timing mark outward. CAUTION: If camshaft sprocket was removed, install NEW camshaft sprocket bolt. DO NOT reuse bolt. 2. Install NEW camshaft sprocket bolt, and tighten to specification while holding camshaft with camshaft sprocket holder. See TORQUE SPECIFICATIONS. 3. Align camshaft sprocket timing mark with pointer. Align crankshaft so number one piston is at TDC (top dead center) as indicated by timing mark. Tuesday, February 16, :23:07 PM Page Mitchell Repair Information Company, LLC.

7 On Federal emissions and all A/T vehicles, it is not necessary to align the auxiliary shart sprocket. 4. On M/T models with CA emissions, to align auxiliary shaft sprocket, install Synchronizer Positioner (T93P A) into synchronizer. Rotate auxiliary shaft sprocket until the synchronizer shutter is against the stop, and the notch of the tool engages the notch of the synchronizer bowl. 5. On all models, install timing belt over crankshaft sprocket, then counterclockwise over auxiliary shaft and camshaft sprockets. Loosen belt tensioner bolt, allowing tension to be applied on timing belt. It may be necessary to push belt tensioner against timing belt, as spring tension may not move belt tensioner against timing belt. 6. Remove synchronizer positioner from synchronizer, if necessary. Remove one spark plug from each cylinder. Rotate engine clockwise (viewed from front of engine) 2 complete revolutions. Bring crankshaft slowly, without stopping, to No. 1 cylinder firing position (keyway directly up). Ensure all timing marks align properly. See Fig Using torque wrench set up to ft. lbs. (41-45 N.m), rotate tensioner assembly against bolt and tighten timing belt tensioner bolts to specification. See TORQUE SPECIFICATIONS. 8. Install belt guide on crankshaft. Install crankshaft sensor over dowel pins. Tighten long crankshaft sensor bolts to 6-9 ft. lbs. (8-12 N.m). 9. Install hub assembly and crankshaft pulley. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Install crankshaft sensor positioner. See Fig. 3. Rotate crankshaft clockwise approximately 90 degrees so outer vane of hub assembly engages with crankshaft sensor positioner. Tighten short crankshaft sensor bolts to INCH lbs. ( N.m). 10. Rotate crankshaft counterclockwise 90 degrees, and remove crankshaft sensor positioner. Rotate crankshaft 90 degrees clockwise, and measure the outer vane-to-sensor air gap. The air gap must be " ( mm). 11. To install remaining components, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. 12. Disconnect heater hose from fitting on thermostat housing to bleed air from cooling system when filling. Fill cooling system with Ford Coolant (E2FZ AA), or equivalent, until coolant flows from fitting. Install heater hose. Refill radiator. Adjust drive belts to proper tension. Tuesday, February 16, :23:07 PM Page Mitchell Repair Information Company, LLC.

1991 Nissan 240SX. 2.4L 4-CYL - VINS [F,M,S] 1991 ENGINES Nissan 2.4L 4-Cylinder

1991 Nissan 240SX. 2.4L 4-CYL - VINS [F,M,S] 1991 ENGINES Nissan 2.4L 4-Cylinder NOTE: Use illustration for component reference. See Fig. 7. 1. Remove spark plug wires. Set No. 1 piston at TDC on its compression stroke. Remove vacuum hoses, electrical harnesses, connectors, and harness