Campaign - Engine Drive Belt Tensioner Bolt Replacement: Overview

09-007

January 30, 2009

Applies To:
See VEHICLES AFFECTED

Product Update: Drive Belt Auto-Tensioner Pivot Bolt Replacement

BACKGROUND

The current routing of the engine drive belt creates extra force on the drive belt auto-tensioner. In rare cases, this extra force could break the auto-tensioner pivot bolt, causing an engine noise or a loss of power steering.





VEHICLES AFFECTED

CUSTOMER NOTIFICATION

Owners of affected vehicles will be sent a notification of this product update. An example of the customer notification is at the end of this service bulletin.

CORRECTIVE ACTION

Replace the auto-tensioner pivot bolt, and reroute the drive belt. On vehicles with A/C, install a new drive belt.





PARTS INFORMATION





REQUIRED SPECIAL TOOLS

WARRANTY CLAIM INFORMATION

NOTE:
This product update ends on January 30, 2012. After that, any applicable warranty would apply.

Operation Number: 1181L1

Flat Rate Time: 0.5 hour

Failed Part: P/N 04301-RNA-405
H/C 9175126

Defect Code: 5TT00

Symptom Code: R0100

Template ID: 09-007A

Skill Level: Repair Technician

REPAIR PROCEDURE





1. From above the engine, set a long-handled, boxed-end wrench on the drive belt auto-tensioner. Slowly turn the wrench counterclockwise, then remove the drive belt.

NOTE:
On vehicles without A/C, the drive belt will be reused.





2. Insert a pulley holder (see REQUIRED SPECIAL TOOLS) into one of the holes in the water pump pulley at the 12 o'clock position. The tool holds the pulley so you can loosen or tighten the pulley bolts.

3. Remove the water pump pulley (three bolts).

4. Remove the pivot bolt from the drive belt auto-tensioner.





NOTE:
In rare cases, the pivot bolt may be broken. If this has happened, remove the auto-tensioner, then remove the shank of the pivot bolt with Vise Grips or by drilling it out. Do not try to repair the engine block using a TIME-SERT. If you can't remove the shank of the pivot bolt, you would need
DPSM approval to install an engine short block assembly.

5. Install a new pivot bolt on the auto-tensioner, and torque it to 54 N.m (40 lb-ft).

NOTE:
For important tips on correctly installing the pivot bolt, refer to ServiceNews article A07030I, Replacing the Drive Belt Auto-tensioner Pivot Bolt? Read This First.

6. Reinstall the water pump pulley and its three bolts. Insert the pulley holder in the 12 o'clock position to keep the pulley from moving while you torque the bolts to 14 N.m (10 lb-ft).





NOTE:
^ The exact torque is critical for a successful repair. To guarantee the correct torque, you must use an accurately calibrated torque wrench. It's OK to use a crowfoot socket wrench with the torque wrench.

^ Do not install the drive belt before you torque the pulley bolts. If you do, you won't get accurate torque readings.

^ Remove the pulley holder after you torque the pulley bolts.





7. On vehicles with A/C, route a new drive belt around the engine pulleys as shown above. On vehicles without A/C, route the original drive belt as shown in step 1.

8. From above the engine, set a long-handled boxed-end wrench on the drive belt auto-tensioner. Slowly turn the wrench counterclockwise, and slip the belt over the auto-tensioner pulley. Release the auto-tensioner, and remove the wrench.





9. Center-punch a completion mark below the 13th character of the engine compartment VIN:

^ Slide open the FRAME NUMBER door on the center cowl cover.

^ Use a long punch to reach the VIN.