Everest Hyundai 408/650 Timing Belt Removal & Replacement. Prochem Tech Support Team

Transcription

1 Everest Hyundai 408/650 Timing Belt Removal & Replacement Prochem Tech Support Team

2 Introduction l The Timing Belt needs to be changed every 2 years or 2,000 hours, which ever comes first. l Tools that will be required. l Step by Step Instructions. 2

3 Tools Required l l Sockets - ½" drive 12mm, 22mm, 3/4" Sockets - 3/8" drive 8mm, 11mm, 12mm l Hex Key (Allen) 3/16" l l l l Torque wrench Pry bars small & medium Box End 2ea - 3/4 2ea -7/16", 1ea- 13mm Red hydraulic thread lock 3

4 Getting Started l Disconnect battery l Adhere to all standard safety procedures and cautions for your shop environment l Lay out tools & rags 4

5 Remove Front Cover Step 1 l Tools 7/16" socket and back up wrench Remove 2ea bolts View behind right side panel 5

6 Remove Front Cover Step 2 l Tools- 3/16" Hex Key (Allen), 7/16" socket and back up wrench Remove 7/16 bolt Remove 3/16" hex bolt View behind left side of front panel 6

7 Remove Front Cover Step 3 l Tools 7/16" socket Remove 5ea ¼" nuts from the cover mounting studs View under top of front cover 7

8 Remove Front Cover Step 4 Set front cover aside to expose the radiator view from the side doors of the van 8

9 Loosen Alternator / Fan Belt Step 1 l Tools 12mm Socket loosen the side locking nut located on the alternator bracket as shown View from the right side of the engine 9

10 Loosen Alternator / Fan Belt Step 2 l Tools 12mm socket Adjust the jack bolt as shown to loosen the fan belt. 10

11 Reposition The Radiator It will be necessary to reposition the radiator but will be done without removing the radiator or even draining the coolant 11

12 Reposition The Radiator Step 1 l Tools 3/4" box end Remove the nut from the main mounting bracket between the radiator and the engine View right side between radiator & engine 12

13 Reposition The Radiator Step 2 l Tools 3/4" Box End Remove the nut from the main mounting bracket between the radiator and the engine View left side between radiator & engine 13

14 Reposition The Radiator Step 3 l Remove upper mounting bolts l Tools 13mm box end wrench Remove bolts from both sides View from above, looking behind the radiator 14

15 Reposition The Radiator Step 4 l Tools 7/16" socket Remove this last bolt that holds the radiator in place. View upper left of radiator 15

16 Reposition The Radiator Step 5 l Pivot Radiator To The Right Side Of The Machine Keep radiator mount against the radiator bracket, using it as a guide to keep the radiator from interfering with the fan blades 16

17 Remove the Fan & Pulleys l Tools 10mm socket * Reassembly note Remove 4ea bolts Remove the fan, belt, and pulleys * Torque fan bolts to 12 ft lbs use blue thread lock 17

18 Remove Crank Pulley l Tools - 22mm socket * Reassembly note Loosen the crank pulley bolt Secure the flywheel as required to loosen the crank pulley bolt, and remove the pulley * Torque crank pulley bolt between ft. lbs 18

19 Remove the Upper Belt Cover l Tools 10mm socket * Reassembly note Remove the 4 bolts and lift the cover up as shown * Torque cover bolts between 6-7 ft lbs 19

20 Remove the Lower Belt Cover l Tools 10mm socket * Reassembly note Remove the 5 mounting bolts as shown and remove the cover * Torque cover bolts between 6-7 ft lbs 20

21 Remove the Belt Tension Step 1 l Tools 12mm socket * Reassembly note Important Note: Do not allow the crank or cam sprockets to turn once the tension is off the belt. Loosen (do not remove) tensioner spring bolt as shown * Torque tensioner spring bolt between ft lbs 21

22 Remove the Belt Tension Step 2 l Tools 12mm socket * Reassembly note Remove the tensioner adjustment bolt * Torque tensioner adjustment bolt between ft lbs 22

23 Remove the Belt Tension Step 3 l Tools medium pry bar Pry the idler up to remove the belt tension 23

24 Important Note: Once the Belt is Removed DO NOT turn the crank or cam shaft until the belt has been completely installed. If the timing marks on either the crank or cam sprocket move independently, it will be necessary to follow the timing procedure as described in Zenith Power Products publication: ZPP-416 Engine DOHC 24

25 Remove the Belt The lower gear is loose on the Shaft. Take care not to remove the gear or lose the key 25

26 Inspect Sprocket, Tensioner and Idler Pulleys 1- Check the camshaft sprocket, crankshaft sprocket, tensioner pulley, and idler pulley for abnormal wear, cracks or damage and replace as necessary Tensioner Pulley Camshaft Sprocket Idler Pulley 2 - Inspect the tensioner pulley and the idler pulley for easy and smooth rotation and check for play or noise, replace as necessary Crankshaft Sprocket 3 - Replace the tensioner or idler pulley if there is grease leaking from the bearing 26

27 Replace the Key Should the gear key fall out replace as required 27

28 Install the New Belt Step 1 3 Install in order from: 1- The Crank Shaft Sprocket, counter clockwise 2 2- The Idler Pulley The Camshaft Sprocket, counter clockwise around the sprocket 4- The Tensioner, make certain the belt cogs are fit into the sprockets 28

29 Install the New Belt Step 2 Do not leave slack between center shafts 29

30 Install the New Belt Step 3 The tension can be adjusted by applying pressure in the direction of the blue arrow on the tensioner pulley then tightening the adjustment bolt to hold the position The Tensioner Spring Should automatically adjust to the proper tension however it can be checked by applying approx. 11pounds of moderate force against the belt in the direction and location of the yellow arrow. The belt should deflect approx. to the center of the adjusting bolt head. 30

31 Install the New Belt Step ft lbs ft lbs After setting the belt tension and checking that each timing belt tooth is properly riding in the sprockets and the key is in the crank sprocket & shaft, torque the tensioner spring bolt and tensioner adjustment bolt 31

32 Install the New Belt Final Step l Tools 22mm socket Crank Shaft Insert the crank pulley bolt and washer then turn the crank shaft 2 turns in it s operating direction (clock-wise) then recheck the belt tension and re-tension as required 32

33 Follow the Torque Chart provided below & reassemble in reverse order of this presentation. Crank Shaft Pulley Tensioner Pulley Tensioner Adjustment Bolt Timing Belt Cover Bolts ft lbs ft lbs ft lbs 6-7 ft lbs Fan Bolts use Blue Hydraulic Lock 12 ft lbs Alternator Lock bolt 9-11 ft lbs 33

34 Contact Prochem Technical Service Department with Questions or Comments Jerry McKillip Gregg Ingallina Chuck Coffey Extension 5653 Extension 6513 Extension

35 Our sincere gratitude goes to the Dealers and their Mechanics that do a fantastic job supporting Prochem with the highest professional standards and attitudes. Thank You! 35

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