Rotamass Lightweight Pulley Kit

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Paul Blair
7 years ago
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1 Rotamass Lightweight Pulley Kit

2 List of Parts Included List of Required Tools (1) Rotamass Lightweight Puley (1) M16 x 1.5mm x 75mm Bolt with Round Seal (1) 6PK1065 Ribbed Belt (transverse applications) (1) 6PK1535 Ribbed Belt (longitudinal applications) (1) Installation Tool (1) Locking Pin for Belt Tensioner 24mm six point socket (1/2 inch drive) 1/2 inch drive breaker bar 1/2 inch drive torque wrench 15mm end wrench (the longer the better) Flat tip screwdriver For Transverse Motors T-30 socket (3/8 inch drive) 3/8 inch drive ratchet T-25 screwdriver or socket For Longitudinal Motors 7mm socket (1/4 inch or 3/8 inch drive) 1/4 inch or 3/8 inch drive ratchet 13MM Wrench or socket 5MM Wrench or socket or ratchet 11MM Wrench or socket or ratchet

3 Proper service and repair procedures are vital to the safe, reliable operation of all motor vehicles as well as the personal safety of those performing the repairs. Standard safety procedures and precautions (including use of safety goggles and proper tools and equipment) should be followed at all times to eliminate the possibility of personal injury or improper service which could damage the vehicle or compromise its safety.

4 1 TRANSVERSE APPLICATIONS FOLLOW STEPS 1-7 LONGITUDINAL APPLICATIONS FOLLOW STEPS 1a - 7a Remove lower noise insulation from vehicle, Refer to 1 and 2, Use a T-25 screwdriver or socket and pull towards rear of vehicle. 1

5 2 Loosen the fasteners 1, 2 and 3 to remove the right side (passenger) noise insulation. use a T-25 screwdriver or socket with ratchet. 2

6 3 Lift the clamps 1 and 2 using a flat tip screwdriver or pick and then remove the screws with arrows pointing at them with a T-30 socket with ratchet. Remove the air guide pipe. 3

7 4 Release the tension of the ribbed belt by placing a 15mm end wrench on the belt tensioner as shown, rotate the wrench clockwise, insert locking pin into the area shown to lock the tensioner in the open position, remove the ribbed belt. 4

8 5 Rotate the crank pulley to the Top Dead Center (TDC) position using the pulley installtion tool (provided), note the postion in the photo with the arrow, it shows the notch that must line up with the mark on the timing chain lower cover. Remove the crank pulley bolt a 24mm socket and breaker bar. Use the installtion tool provided to hold the pulley in place while loosening (do not allow the crankshaft to be moved out of TDC while the pulley is removed). 5

9 6 Install your Rotamass Lightweight Crank Pulley in the reverse order of removal. Use the new bolt provided. The new bolt contains an o-ring, coat it with oil before installing, coat the sealing lip on the timing chain cover with transmission oil. Torque the bolt to 150nm, plus a 90 degree stretch using the pulley tool provided and a 24mm socket with torque wrench and breaker bar. 6

10 7 Install the new 6PK1065 ribbed belt as shown in the figure below. Use a 15mm wrench to unlock the belt tensioner and remove the locking pin (reverse of step 4). Check whether the belt is routed correctly, install the air guide in the opposite of removal(revrerse of step 3). Clean off any oil or dirt from the air guide prior to reinstallation. Start the engine to verify the belt is running correctly. Reinstall the noise insulation and sound deadeners (reverse of steps 1 and 2). 7

11 1a Remove the front noise insulation from the vehicle, us a flat tip screwdriver or a T-25 screwdriver or socket. 8

12 2a Remove the front end plate from the vehicle by unscrewing the fasteners shown in the figure below (1 & 2) with a T-25 screwdriver or socket with ratchet. 9

13 3a Unplug the electrical connectors shown in the figure below (2 & 3) from the fan motors, remove the fan control module (1) from the fan shroud with a 7mm socket and ratchet as shown with arrow. 10

14 4a Release the tension of the ribbed belt by placing a 15mm end wrench as shown in the figure below and rotating clockwise. Lock the tensioner in the open position utilizing the pin provided. Once locked in place remove the ribbed belt from the engine crank pulley. 11

15 5a Rotate the crank pulley to Top Dead Center (TDC) using the tool provided, the notch in the pulley must line up with the arrow marking on the timing chain cover. Remove the crank pulley bolt with a 24mm socket and breaker bar. Use the tool provided to hold the pulley still while removing the bolt. (do not allow the crankshaft to be moved out of TDC while the pulley is removed). 12

16 6a Install your Rotamass Lightweight Crank Pulley in the reverse order of removal. Use the new bolt provided. The new bolt contains an o-ring, coat it with oil before installing, coat the sealing lip on the timing chain cover with transmission oil. Torque the bolt to 150nm, plus a 90 degree stretch using the pulley tool provided and a 24mm socket with torque wrench and breaker bar. 13

17 7a Install the new 6PK1535 ribbed belt as shown in the figure below. Use a 15mm wrench to unlock the belt tensioner and remove the locking pin (reverse of step 4a). Check whether the belt is routed correctly, Start the engine to verify the belt is running correctly. Reinstall the fan control module (reverse of step 3a), front end plate (reverse of step 2a) and noise insulation (reverse of step 1a). 14

18 LIMITED ONE (1) YEAR WARRANTY Eurocode Tuning, Inc. (EUROCODE) warrants to the original purchaser that our Rotamass Lightweight Pulley (PRODUCT) will be free of defects in material and workmanship for a period of one (1) year from the date of purchase. This Warranty applies only to the original purchaser of the PRODUCT. To obtain any warranty service, you must provide EUROCODE with proof of purchase and date of purchase acceptable to EUROCODE, such as a copy of your purchase receipt. This warranty does not cover the removal or reinstallation of the product. EUROCODE will, at its option, repair, replace or refund the purchase price of a defective component, provided you return the defective component during the warranty period, transportation charges prepaid, to Eurocode Tuning s Service Department or a Factory Authorized Service Center. Attach your name, address, telephone number, a description of the problem, and a copy of your sales receipt. All returns must be accompanied by a Return Goods Authorization (RGA) number and such number shall be written clearly on the outside of the box. RGA numbers may be obtained by calling EUROCODE at This warranty does not apply to the (i) metal finish or (ii) if the product/component has been damaged by accident, abuse, misuse, collision, modification, misapplication, improper installation, or improper service. This warranty is void if any EUROCODE serial number has been removed or defaced. Commercial or industrial use or application, or any motorsports use voids the warranty. THE WARRANTY SET FORTH ABOVE IS THE ONLY WARRANTY. THERE ARE NO OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. ANY IMPLIED WARRANTY WHICH BY LAW MAY NOT BE EXCLUDED IS LIMITED IN DURATION TO ONE (1) YEAR FROM THE DATE OF ORIGINAL RETAIL PURCHASE OF THE PRODUCT.

19 No EUROCODE dealer, agent or employee is authorized to make any modification, extension or addition to this warranty. EUROCODE SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING, BUT NOT LIMITED TO, LOST PROFITS, DOWN TIME OR LOSS OF USE) UNDER ANY LEGAL THEORY, EVEN IF EUROCODE WAS ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. Some states do not allow the exclusion of implied warranties or the exclusion or limitation of liability for incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights. You may also have other rights that vary from state to state. EUROCODE reserves the right to change Product/component design without notice. In situations in which EUROCODE has changed a Product/component design, EUROCODE shall have no obligation to upgrade or otherwise modify previously manufactured Products/components. Warranty inquires and Products returned for warranty service should be sent to: Eurocode Tuning, Inc. Customer Service Department 1872 Del Amo Blvd Unit A Torrance, CA International Fax

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