2003 Saturn Vue. SATURN 3.0L V6 DOHC - L-Series After VIN & Vue

Transcription

1 TIMING BELT Removal 1. Disconnect negative battery cable. Remove air cleaner assembly. 2. Raise and support vehicle. Remove right front wheel. Remove lower front splash shield. 3. Lower vehicle. Loosen, but DO NOT remove, water pump pulley bolts. Rotate accessory serpentine belt tensioner clockwise using a 15 mm wrench, and remove accessory serpentine belt from pulleys. NOTE: Right engine mount must be removed before accessory drive belt can be removed from vehicle. 4. Install the 3 Bar Engine Support Fixture (SA9105E) and the Engine Support Fixture Adapter (J-43405) to support weight of engine from above or from below with a floor jack. Remove front engine mount (timing belt end of engine) from engine and frame. 5. Remove water pump pulley bolts and pulley. Remove the power steering pump pulley bolts and pulley. Remove accessory drive belt tensioner from engine block. 6. Remove 6 harmonic balancer-to-crankshaft bolts. Remove harmonic balancer. It is NOT necessary to remove crankshaft center bolt. 7. Remove wiring harness channel from front timing belt cover, and secure away from engine. Remove front timing belt cover. Inspect sealing strip on outer edge of cover for cracks or tears. Replace, if necessary. 8. Rotate crankshaft clockwise to 60 degrees Before Top Dead Center (BTDC). See Fig Install Crankshaft Locking Tool (J ). Rotate the crankshaft in the engine rotational direction, clockwise, using the Crank Hub TORX Socket (J-42098) until the No. 1 cylinder is at TDC and tighten the lever arm to the water pump pulley flange. See Fig. 2. NOTE: Ensure timing marks are not 180 degrees from TDC. Camshaft timing marks should be aligned with marks on rear cover. See Fig To lock camshafts in place, install Camshaft Gear Holders 1-2 (J ) and 3-4 (J ). See Fig. 4. It may be necessary to loosen timing belt idler pulley and turn eccentric until holder can be inserted. 11. Loosen timing belt tensioner. Remove timing belt. CAUTION: DO NOT remove Camshaft Holders (J-42069) with timing belt removed. CAUTION: DO NOT rotate crankshaft unless camshafts are properly locked in place, or valves may contact pistons. CAUTION: DO NOT rotate camshafts unless crankshaft in at 60 BTDC, or valves may contact pistons. Saturday, January 31, :28:32 3:28:37 PM Page Mitchell Repair Information Company, LLC.

2 Fig. 1: Positioning Crankshaft At 60 BTDC Saturday, January 31, :28:32 PM Page Mitchell Repair Information Company, LLC.

3 Fig. 2: Installing Crankshaft Holder Saturday, January 31, :28:32 PM Page Mitchell Repair Information Company, LLC.

4 Fig. 3: Aligning Timing Belt Marks With Rear Cover Marks Saturday, January 31, :28:32 PM Page Mitchell Repair Information Company, LLC.

5 Fig. 4: Installing Camshaft Gear Holders Inspection Check timing belt for excessive wear, cracks, missing teeth, oil contamination or damage. Inspect timing belt tensioner and idler pulleys for grease leaks or worn bearings. Replace as necessary. CAUTION: DO NOT kink belt or a NEW belt will be required. Installation 1. Remove crankshaft holder. This will ease installation of the timing belt. Saturday, January 31, :28:32 PM Page Mitchell Repair Information Company, LLC.

6 NOTE: With the camshaft locks installed, verify the distance between the camshaft sprockets with the Green test belt located in the Timing Belt Alignment Kit (J-42069). 2. Starting at the No. 1 and No. 2 camshaft sprockets, route the belt around the No. 1 and No. 2 sprockets while aligning the belt marks to the marks on the sprockets and the rear cover. See Fig. 3. Keeping slack out of belt, route timing belt around tensioner and upper idler pulley. NOTE: Use the marks on each side of the direction of rotation arrows to line up the left (driver's side) camshaft sprockets. For this design (idler pulley located above crankshaft) engine, use the remaining 3 White marks on the timing belt. Correct belt marks MUST be used. 3. Route the belt around the No. 3 and the No. 4 camshaft sprockets while aligning the belt marks to the marks on the sprockets and the rear cover. Route the belt around the crankshaft hub sprockets while aligning the marks on the belt to the marks on the sprockets and the rear cover. See Fig. 5. Hold timing belt in place against crankshaft sprocket using Plastic Wedge (J ). Saturday, January 31, :28:32 PM Page Mitchell Repair Information Company, LLC.

7 Fig. 5: Aligning Timing Belt Marks On Crankshaft Pulley 4. With belt firmly engaged on crankshaft sprocket, carefully rotate crankshaft counterclockwise to allow slack at lower idler pulley side of belt. Install belt over lower idler pulley. Remove plastic wedge holding timing belt against crankshaft sprocket. 5. Install the crankshaft locking tool and tighten the lever arm to the water pump pulley flange. Perform the following in sequence: A. Install the camshaft checking gage to cams 3 and 4 and verify the alignment marks are within Saturday, January 31, :28:32 PM Page Mitchell Repair Information Company, LLC.

8 0.08" (2 mm) of each other. B. Install the 3 and 4 camshaft lock, if properly aligned. C. Install the camshaft checking gage to cams 1 and Rotate the No. 1 camshaft sprocket counterclockwise to remove the slack between 1 and 2, and 3 and 4 cams. NOTE: Ensure that the camshaft timing marks are to the left (retard) side of the checking gage. 7. Rotate upper timing belt idler pulley counterclockwise so that marks are aligned within 0.08" (2.0 mm) of each other. Install 1-2 camshaft lock after aligning idler pulley. Tighten idler pulley bolt to specification. See TORQUE SPECIFICATIONS. 8. Turn tensioner eccentric until center alignment mark is about 1/8" (3.0 mm) above alignment mark on spring loaded idler pulley. See Fig. 6. Saturday, January 31, :28:32 PM Page Mitchell Repair Information Company, LLC.

9 Fig. 6: Setting Timing Belt Tension Setting CAUTION: If TDC is passed while rotating crankshaft, DO NOT turn crankshaft counterclockwise. This will take out correct timing belt tension between timing belt tensioner and crankshaft sprocket. To correct for this, rotate crankshaft 2 additional turns. 9. Remove camshaft holders from camshaft sprockets. Remove crankshaft locking tool. Rotate crankshaft 1-3/4 turns clockwise, install crankshaft locking tool and then stop rotating crankshaft at TDC. Secure crankshaft locking tool arm to water pump pulley flange. 10. Install Checking Gauge (J ) to left hand (driver's side) camshafts. See Fig. 7. Verify marks are within 0.08" (2.0 mm) of each other. Adjust timing belt tensioner so center alignment mark is Saturday, January 31, :28:32 PM Page Mitchell Repair Information Company, LLC.

10 approximately 1/8" (3.0 mm) above mark on spring loaded idler pulley. Tighten tensioner pulley bolt to specification. See TORQUE SPECIFICATIONS. Fig. 7: Positioning Timing Belt On Left Hand Camshafts 11. Verify the timing marks are still aligned. Remove Crankshaft Holder (J ). Remove Checking Gauge (J ). Install timing belt front cover. Install crankshaft harmonic balancer. Tighten bolts to specification. See TORQUE SPECIFICATIONS. 12. Install water pump and accessory drive belt idler pulleys. Install accessory drive belt tensioner. Install accessory drive belt. Tighten pulley and idler bolts to specification. Install engine mount. Connect negative battery cable. 13. Raise vehicle. Install splash shield. Install wheel. Lower vehicle and install air cleaner assembly. Saturday, January 31, :28:32 PM Page Mitchell Repair Information Company, LLC.