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Re: serpentine belt is too short now
Only one tensioner,what i do when i touch one is to draw the way its fitted then i cant forget it ,and yes evan us so called professionals do it .Evan forget to tighten wheel nuts when phone has rung,best advice i can give is see if a neighbour has one and look at theirs,or what i have done before now as iam too vain to ask and that was to drop something in the shopping mall and have a crafty look .
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Pull your Serpentine belt, remove the Cam Belt Cover, (it may be advantageous to remove front wheel in the Cam Belt side) Remove the timing belt and time the engine to specifications, make sure you are on #1TDC, remove the tensioner and replace. if there is and Idler pulley replace that as well. You can use Spray Carb Cleaner to clean the pulleys before replacing the belt. Note, you may have to also remove the Harmonic Balancer and pulleys from the crankshaft.
1. Remove the timing chain cover. Its usually a black plastic cover on the side of the engine. 2. Loosen the timing belt tensioner. Its cylindrical shape thing made of metal and timing belt run over it. 3. After loosening it you can remove the old belt and place new belt. 4. Tighten the belt tensioner and put timing belt cover back. Done.
Remove the alternator. Remove the drive belt idler. Remove the drive belt tensioner. Remove the water pump pulley. Remove the intake manifold.
Remove the connector bracket from the left cylinder head cover. Disconnect the right ignition coil connector, condenser connector and remove the bracket.
Remove the left cylinder head cover retaining bolts. Remove the cylinder head cover from the engine.
Remove the right cylinder head cover retaining bolts. Remove the cylinder head cover from the engine.
Set the No. 1 cylinder to TDC on the compression stroke. Turn the crankshaft pulley and align its groove with the timing mark T of the lower timing chain cover.
Check that the mark of the camshaft timing sprockets are in straight line positioning on the cylinder head surface. If not rotate the crankshaft 360 degrees. Do not rotate the engine counterclockwise.
Remove the oil pan. Remove the crankshaft damper pulley. Remove the timing chain cover.
Be careful not to damage the contact surfaces of the cylinder block, cylinder head and timing chain cover. Before removing the timing chain, mark the right and left timing chains with an identification mark based on the location of the sprocket because the identification mark on the chain for TDC can be erased.
After compressing the timing chain tensioner, install a set pin. Remove the right cam to cam guide. Remove the right timing chain auto tensioner and timing chain tensioner arm.
Remove the oil pump chain cover. Remove the oil pump chain tensioner assembly. Remove the oil pump chain guide. Remove the right timing chain.
Remove the right timing chain guide. Remove the oil pump chain sprocket and oil pump chain. Remove the crankshaft sprocket, oil pump and camshaft drive gear.
Remove the left cam to cam guide. Remove the left timing chain auto tensioner and timing chain tensioner arm. Remove the left timing chain.
Remove the left timing chain guide. Remove the crankshaft sprocket and left camshaft drive. Remove the tensioner adapter assembly.
Fig. Timing chain and related components-3.8L Engine
Check the camshaft and crankshaft sprockets for wear and damage, replace as required.
Inspect the tensioner arm and chain guide for wear and damage, replace as required.
Check that the tensioner pin moves smoothly when the ratchet pawl is released with a thin rod.
The key of the crankshaft should be aligned with the timing mark of the timing chain cover. This indicates that the piston is at TDC on the compression stroke.
Install the tensioner adapter assembly. Install the crankshaft sprocket and left camshaft drive.
Install the left timing chain guide and torque the retaining bolts 14-18 ft. lbs.
Install the left timing chain. Be sure to install the chain with no slack between the camshaft and the crankshaft (crankshaft sprocket, timing chain guide, exhaust camshaft sprocket, intake camshaft sprocket). The timing mark of each sprocket should be matched with the timing mark (color ink) of the timing chain at installation of the timing chain.
Fig. Left timing chain markings and installation: (D) exhaust camshaft sprocket (C) intake camshaft sprocket-3.8L Engine
Install the left timing chain tensioner arm and torque the retaining bolts 14-16 ft. lbs.
Install the left timing chain tensioner and torque the retaining bolts 7-9 ft. lbs.
Install the left cam to cam guide and torque the retaining bolts 7-9 ft. lbs.
Install the crankshaft sprocket, oil pump and right camshaft drive.
Install the oil pump chain and oil pump sprocket. Torque the retaining bolt to 14-16 ft. lbs.
Install the right timing chain guide. Torque the retaining bolts to 14-18 ft. lbs.
Install the right timing chain. Be sure to install the chain with no slack between the camshaft and the crankshaft (crankshaft sprocket, intake camshaft sprocket, exhaust camshaft sprocket). The timing mark of each sprocket should be matched with the timing mark (color ink) of the timing chain at installation of the timing chain.
Fig. Right timing chain markings and installation: (C) exhaust camshaft sprocket (B) intake camshaft sprocket-3.8L Engine
Install the right timing chain tensioner arm. Torque the retaining bolts to 14-17 ft. lbs.
Install the right timing chain auto tensioner. Torque the retaining bolts to 7-9 ft. lbs.
Install the right cam to cam guide and torque the retaining bolts to 7-9 ft. lbs.
Install the oil pump chain guide. Torque the retaining bolts to 7-9 ft. lbs.
Install the oil pump tensioner assembly. Torque the retaining bolts to 7-9 ft. lbs.
Pull out the pins on both the left and right hydraulic tensioners. Install the oil pump chain cover.
Rotate the crankshaft two revolutions in the clockwise direction. Confirm the timing mark. Be sure to rotate the crankshaft in the clockwise direction.
Apply sealant on the chain cover and on the cylinder head, cylinder block, and lower oil pan. Be sure these parts are free of engine oil and dirt.
Before assembling the timing chain cover, the liquid sealant TB1217H should be applied on the gap between the cylinder head and block. The part must be assembled with five minutes after the sealant is applied.
Fig. Sealant application (1 inch bead width)-3.8L Engine
Apply sealant on the chain cover.
The liquid sealant TB1217H should be applied on the gap between the cylinder head and block. The part must be assembled with five minutes after the sealant is applied.
Fig. Timing cover sealant application-3.8L Engine
Install a new gasket to the timing case cover.
It is important that the dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in order to assemble the timing chain cover in the correct position.
the water pump is under the timing chain cover. if your serpentine belt is loose, that is the belt you can see, then your tensioner is shot. you can buy a new tensioner for about 50 bucks at a parts store. search on www.youtube.com for video directions on how to replace it. if your serpentine belt has not been changed this is a good time to do that as well as it has to come off. replacement of the tensioner and belt is done via a service panel behind the right front wheel.
Install a bolt in the end of the crankshaft
CAUTION Do not install the crankshaft balancer bolt or a bolt longer than 1 inch or damage to the crankshaft threaded hole will result.
Rotate crankshaft until the number 1 piston is at Top Dead Center of compression stroke.
Make sure that the alignment marks are aligned with the tabs on the timing chain tensioner.
Measure distance between hole in bracket and unworn surface of timing chain tensioner shoe.
NOTE: If distance between the hole and unworn surface of timing chain tensioner is greater than 0.314 in (8 mm), replace tensioner, timing chain and sprockets.
Remove timing chain tensioner bolts.
Remove the timing chain, timing chain tensioner and camshaft sprocket at the same time.
Remove the crankshaft sprocket using special tool J 22888-20A or equivalent.
Remove crankshaft sprocket alignment key.
NOTE: If any camshaft components are being replaced to correct a noise problem, all camshaft drive components must be replaced. To Install:
Install the crankshaft sprocket alignment key.
Install the crankshaft sprocket using special tool J 5590 or equivalent.
Compress the timing chain tensioner spring and insert a pin into the tensioner hole to retain the tensioner shoe.
Install timing chain and timing chain tensioner (do not tighten tension bolts).
Align the crankshaft and camshaft timing marks with the tab on the timing chain tensioner.
Tighten the timing chain tensioner bolts.
Torque to: 18 ft lbs (24 Nm)
Tighten the camshaft sprocket bolt.
Torque to: 96 ft lbs (130 Nm)
Remove pin from timing chain tensioner hole.
Remove bolt from end of crankshaft.
CAUTION Inspect the timing chain cover for warping or damage. Replace if needed.
Clean all timing chain cover mating surfaces.
Install or connect the following:
Timing chain cover to the engine block
Ensure that the gasket is installed properly in the groove in the timing chain cover
Timing chain cover and make sure it fully seated on the alignment dowel pins
GENERAL/Standard Rules to Removal the Serpentine Belt with a Tensioner: A. Find the Tensioner(s). (See Diagrams on Link) B. Using a Serpentine Belt Tensioner Tool, Or Wrench OR Ratchet, Rotate/Move the Tensioner USING THE AVAILABLE NUT (on the Pulley or Arm Base) OR the OPENING (3/8ths or 1/2 inch square opening) rotating the Tensioner Pulley/Arm - moving it away from contact with the belt and towards the area where the belt is not in contact with the Tensioner Pulley. The Tensioner is spring loaded, and is hard to rotate/move. C. Remove the loosened belt off one of the other more easily accessed Pulleys. D. DO NOT quickly release the Tensioner, but gently allow the Tensioner to rest in its closed position.
Standard Rules for Installing the Serpentine Belt with Tensioners: a. Pick a Pulley that is most easily accessed. This will usually be on top. This will be the last Pulley that the belt will go on. b. Using the Diagram: Install the new Serpentine Belt on the remainder of the Pulleys....over, under, left right. c. Using a Serpentine Belt Tensioner Tool or Wrench or Ratchet Tool: Rotate/Move the Tensioner Pulley/Arm "away" from Belt contact area on the Tensioner. This spring is pretty hard and with a new belt, it will be even harder to install. Rotate/Move this to as-close to the maximum allowed inorder to have enough slack in the belt to get it up and over the last pulley. d. Using your other hand - Pull the Belt up and over the Last remaining Pulley. e. Before releasing the pressure on the Tensioner, visually inspect the remainder Pulleys and the Belts' Positioning on them
Let me know if this helped, or if you have additional information or questions. Feel Free to contact me at FixYa.Com!
support engine. remove coolant reservoir. remove serpentine belt. remove serpentine belt tensioner. remove bolts from mount. carefully raise engine up and move mount out of the way.(hard to explain and this is hard to do you have to have the engine in the perfect position and whatnot) remove the top plastic cover. with 19mm socket rotate engine clockwise until hole in cam lines up with hole in head. insert vw special tool to hold cam. remove the 4 6mm bolts on crank pulley. remove plastic covers. with white paint, mark belt to cam and belt to crank. loosen tensioner. remove belt. transfer marks to new belt. strongly suggest replacing water pump. reinstall t-belt. put the tensioner somewhat tight. rotate the engine fully twice. loosen tensioner bolt and adjust to perfect tension using needle and v-groove on adjuster. install is reverse of removal.
3. REMOVE FAN AND GENERATOR V BELT (a) While turning the belt tensioner counterclockwise, align the service hole for the belt tensioner and the belt tensioner fixing position, and then insert a bar of [diameter]5 mm (0.197 in.) into the service hole to fix the belt tensioner in place. HINT: The pulley bolt for the belt tensioner has a left-hand thread. (b) Remove the V belt.
1. INSTALL FAN AND GENERATOR V BELT (a) Set the V belt onto every part. (b) While turning the belt tensioner counterclockwise, remove the pin. NOTICE: Make sure that the V belt is properly set to each pulley. (c) After installing the belt, check that it fits properly in the ribbed grooves. HINT: Make sure to check by hand that the belt has not slipped out of the grooves on the bottom of the pulley. 2. INSTALL NO. 1 ENGINE UNDER COVER 3. INSTALL V-BANK COVER SUB-ASSEMBLY
This is a job for an experienced technician. Probably about a $300 job. Maybe more.
Here is procedure for 1996:
Drain the cooling system. Refer to Section 03-03 for the procedure.
Disconnect the battery ground cable (14301).
Remove the generator drive belt, water pump and power steering pump drive belt, and the A/C compressor drive belt (if equipped). Refer to Section 03-05 for the removal procedure.
If equipped, remove the three A/C compressor drive belt idler pulley bolts and the A/C compressor drive belt idler pulley.
Remove the upper radiator hose bracket bolt.
Loosen the two upper radiator hose clamps and remove the radiator hose bracket bolt. Remove the upper radiator hose (8260) and the upper radiator hose bracket from the vehicle.
Remove the water bypass hose (8597) from between the thermostat housing and the water hose connection (8592).
Remove the main wiring harness from the upper engine front cover (6019).
Remove the eight upper engine front cover bolts and the upper engine front cover.
Raise and support the vehicle.
Remove the RH front wheel and tire assembly.
Remove the four RH outer engine and transmission splash shield bolts and two screws and remove the RH outer engine and transmission splash shield (6775).
Use Strap Wrench D85L-6000-A or equivalent to hold the water pump pulley (8509) while removing the four water pump pulley bolts.
Remove the water pump pulley from the water pump (8501).
Remove the crankshaft pulley (6312). Refer to the procedure in this section.
Remove the five lower engine front cover bolts and the lower engine front cover.
Ensure that the timing marks between the crankshaft sprocket (6306) and the oil pump housing line up.
18. NOTE: The directional arrow is necessary to ensure that the timing chain/belt (6268) can be reinstalled in the same direction.
If the timing chain/belt is to be reused, mark the direction of rotation on the timing chain/belt.
19. Loosen the timing chain/belt tensioner nut.
Remove the timing chain/belt.
Installation NOTE: Ensure that the timing marks on the camshaft sprockets (6256) and the seal plate are properly aligned. Ensure that the timing marks on the crankshaft sprocket and the oil pump housing are still aligned.
CAUTION: Pay special attention to the tooth shape of the timing belt. The current timing belts are not interchangeable with the timing belts from the 1993 model year. The 1993 model year uses a square or trapezoidal tooth timing belt while the current model year uses a rounded tooth design. The design change was made to extend the service life of the timing belt from 60,000 miles for the square or trapezoidal toothed belt to 105,000 miles for the rounded tooth belt. If the proper timing belt is not used, the customer may complain of a "whining" noise coming from the engine compartment. If the camshaft sprocket has a square cut in the valley of the gear tooth, it will require a square or trapezoidal tooth timing belt. If the camshaft sprocket has a rounded cut in the valley of the gear tooth, it will require a rounded tooth timing belt. NOTE: If a new timing chain/belt is to be installed, make sure that the arrow is pointing away from the engine. If a timing chain/belt is to be reused, make sure that the directional arrow that was marked during disassembly is facing the correct direction.
NOTE: A new timing chain/belt has three white timing marks that indicate the correct timing positions of the camshafts and the crankshaft. These marks will help ensure that the engine (6007) is timed properly. When the engine is properly timed each white timing mark on the timing chain/belt will be aligned with the corresponding camshaft and crankshaft timing mark on the sprocket. Because the white timing marks are not evenly spaced you will need to refer to the following illustration for proper timing chain/belt placement. There should be 40 timing belt teeth between the timing marks of the front and rear camshaft sprockets and 43 teeth between the timing mark on the front camshaft sprocket and the timing mark on the crankshaft sprocket.
NOTE: Verify that the camshaft timing marks are aligned with the timing marks on the seal plate, and that the crankshaft sprocket timing mark is aligned with the timing mark on the oil pump (6600).
Install the timing chain/belt starting at the crankshaft sprocket and moving around to the camshaft sprockets following a counterclockwise path. Do not allow any slack in the timing chain/belt between the timing sprockets. After all of the timing marks are matched up with the timing chain/belt installed, slip the timing chain/belt onto the timing chain/belt tensioner.
While holding the timing chain/belt tensioner with an Allen wrench, loosen the timing chain/belt tensioner nut.
Allow the timing chain/belt tensioner to put pressure on the timing chain/belt.
Use an Allen wrench to turn the timing chain/belt tensioner 70-80 degrees clockwise and tighten the timing chain/belt tensioner nut to 43-58 Nm (32-43 lb-ft).
Rotate the crankshaft (6303) clockwise twice and align the No. 1 piston to Top Dead Center (TDC) on its compression stroke.
Apply 98N (22 lbs) of force on the timing chain/belt between the rear camshaft sprocket and the timing chain/belt tensioner.
NOTE: An assistant may be needed to adjust the timing chain/belt.
While holding the timing chain/belt tensioner steady with an Allen wrench, loosen the timing chain/belt tensioner nut. Remove the Allen wrench and adjust the timing chain/belt tensioner as follows:
Install a 0.35mm (0.0138 inch) thick and 12.7mm (0.500 inch) wide feeler gauge as shown.
Turn the crankshaft clockwise to position the feeler gauge between the timing chain/belt tensioner and the timing chain/belt
Tighten the timing chain/belt tensioner nut to 43-58 Nm (32-43 lb-ft).
Turn the crankshaft clockwise to remove the feeler gauge from between the timing chain/belt tensioner and the timing chain/belt.
Rotate the crankshaft clockwise twice and align the No. 1 piston to TDC on its compression stroke.
Apply 98N (22 lbs) of force on the timing chain/belt between the rear and front camshaft sprocket.
Measure the timing chain/belt deflection. Timing chain/belt deflection should be between 13-15mm (0.51-0.59 inch). If timing chain/belt deflection is not within specification, repeat steps 3-11. If the timing chain/belt cannot be adjusted to within specification, the timing chain/belt will have to be replaced.
Position the lower engine front cover and install the five lower engine front cover bolts. Tighten the five lower engine front cover bolts to 3-5 Nm (27-44 lb-in).
Install the outer timing chain/belt guide and the crankshaft pulley. Refer to the procedure in this section.
Position the water pump pulley on the water pump and install the four water pump pulley bolts
Use Strap Wrench D85L-6000-A or equivalent to hold the water pump pulley, and tighten the four water pump pulley bolts to 16-21 Nm (12-15 lb-ft).
Position the RH outer engine and transmission splash shield and install the four RH outer engine and transmission splash shield bolts and two screws.
Install the RH front wheel and tire assembly. Tighten the lug nuts (1012) to 98-118 Nm (72-87 lb-ft).