Chrysler RG Voyager. Manual — part 485
INSTALLATION
(1) Install timing belt idler pulleys (Fig. 108).
Torque bolts to 47.1N·m.
(2) Install timing belt (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - INSTALLATION).
(3) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(4) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(5) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(6) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(7) Install right engine mount.
(8) Install air cleaner housing.
(9) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(10) Connect negative battery cable.
TIMING BELT TENSIONER &
PULLEY
REMOVAL
CAUTION: INSPECT THE TOOTHED BELT, PULLEYS
AND BEARINGS FOR DAMAGE, SEIZURE AND
LEAKS.
NOTE: DO NOT expose the toothed belt to oil,
grease or water contamination. DO NOT clean belt,
pulleys or tensioner with solvent. DO NOT crimp
the timing belt at a sharp angle. DO NOT install belt
with levered tools forcing the belt onto the pulleys.
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove air cleaner housing.
(4) Support
engine
and
remove
right
engine
mount.
(5) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(7) Remove
vibration
damper
(Refer
to
9
-
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(8) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(9) Loosen and remove timing belt tensioner (Fig.
109).
INSTALLATION
CAUTION: INSPECT THE TOOTHED BELT, PULLEYS
AND BEARINGS FOR DAMAGE, SEIZURE AND
LEAKS.
NOTE: DO NOT expose the toothed belt to oil,
grease or water contamination. DO NOT clean belt,
pulleys or tensioner with solvent. DO NOT crimp
the timing belt at a sharp angle. DO NOT install belt
with levered tools forcing the belt onto the pulleys.
(1) Install timing belt tensioner and retaining bolt
(Fig. 109).
(2) Adjust timing belt tensioner (Refer to 9 -
ENGINE/VALVE
TIMING/TMNG
BELT/CHAIN
TENSIONER&PULLEY - ADJUSTMENTS).
Fig. 108 TIMING BELT AND SPROCKETS
1 - CAMSHAFT SPROCKETS
2 - INJECTION PUMP SPROCKET
3 - INJECTION PUMP SPROCKET RETAINING NUT
4 - TIMING BELT TENSIONER
5 - TIMING BELT
6 - IDLER PULLEY
9 - 72
ENGINE
RG
TIMING BELT IDLER PULLEY (Continued)
(3) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(4) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(5) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(6) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(7) Install right engine mount.
(8) Install air cleaner housing.
(9) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(10) Connect negative battery cable.
ADJUSTMENTS
ADJUSTMENT - TIMING BELT TENSIONER
(1) With timing belt outer cover removed and tim-
ing belt installed.
(2) Loosen timing belt tensioner (Fig. 110).
(3) Align timing belt tensioner spring stop with
tensioner as shown (Fig. 111) and torque timing belt
tensioner retaining bolt to 34.7N·m.
Fig. 109 TIMING BELT AND SPROCKETS
1 - CAMSHAFT SPROCKETS
2 - INJECTION PUMP SPROCKET
3 - INJECTION PUMP SPROCKET RETAINING NUT
4 - TIMING BELT TENSIONER
5 - TIMING BELT
6 - IDLER PULLEY
Fig. 110 TIMING BELT TENSIONER ADJUSTMENT
1 - TIMING BELT IDLER PULLEY
2 - ENGINE FRONT COVER
3 - CRANKSHAFT HUB
4 - TIMING BELT TENSIONER
5 - TIMING BELT
Fig. 111 TIMING BELT TENSIONER ALIGNMENT
1 - TENSIONER SPRING STOP
2 - TIMING BELT TENSIONER
3 - TIMING BELT TENSIONER
4 - TIMING BELT
5 - TIMING BELT INNER COVER
RG
ENGINE
9 - 73
TIMING BELT TENSIONER & PULLEY (Continued)
(4) Rotate engine 2 complete revolution and then
recheck
tensioner
alignment.
Readjust
tensioner
alignment as necessary.
TIMING BELT AND
SPROCKETS
REMOVAL
CAUTION: BEFORE REMOVING THE TIMING BELT,
THE ENGINE MUST BE PLACED AT 90° ATDC. FAIL-
URE TO DO SO COULD RESULT IN VALVE AND/OR
PISTON DAMAGE DURING REASSEMBLY. (Refer to
9 - ENGINE/VALVE TIMING - STANDARD PROCE-
DURE)
CAUTION: INSPECT THE TOOTHED BELT, PULLEYS
AND BEARINGS FOR DAMAGE, SEIZURE AND
LEAKS.
NOTE: DO NOT expose the toothed belt to oil,
grease or water contamination. DO NOT clean belt,
pulleys or tensioner with solvent. DO NOT crimp
the timing belt at a sharp angle. DO NOT install belt
with levered tools forcing the belt onto the pulleys.
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove air cleaner housing assembly.
(4) Support
engine
and
remove
right
engine
mount.
(5) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(7) Remove the generator.
(8) Rotate engine until #1 piston is at TDC, crank-
shaft notch on the crankshaft hub will be at 12
o’clock.
(9) Looking at the engine from the belt side, rotate
the crankshaft 90° clockwise.
(10) Install the 90° alignment pin, VM 1068 into
the crankcase threaded hole to lock crankshaft (make
sure the crankshaft will not rotate).
(11) Paint mark the crankshaft hub and the oil
pump cover. This will assist during assembly.
(12) Remove
vibration
damper
(Refer
to
9
-
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(13) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(14) Remove the intake and exhaust camshaft
plugs from the camshaft cover to introduce the cam-
shaft timing pins.
NOTE: If the engine is already timed, install the
camshaft alignment pins (intake cam alignment pin,
VM 1052, exhaust cam alignment pin, VM 1053).
(15) Loosen timing belt tensioner and remove tim-
ing belt (Fig. 112).
(16) Using intake camshaft gear bolt, rotate intake
camshaft until the intake alignment hole lines up
with the hole in the camshaft cover. Install the
intake cam alignment pin VM 1052. Repeat the oper-
ation for the exhaust camshaft with alignment pin
VM 1053 (Fig. 112).
(17) Using VM 1055 hold the cam gears to remove
the bolts.
INSTALLATION
(1) With
both
camshaft
alignment
pins
still
installed and the engine locked at 90° after TDC,
install the timing gears finger tight.
(2) Align timing mark on high pressure injection
pump sprocket with timing mark on cover (Fig. 113).
Fig. 112 TIMING BELT AND SPROCKETS
1 - CAMSHAFT SPROCKETS
2 - INJECTION PUMP SPROCKET
3 - INJECTION PUMP SPROCKET RETAINING NUT
4 - TIMING BELT TENSIONER
5 - TIMING BELT
6 - IDLER PULLEY
9 - 74
ENGINE
RG
TIMING BELT TENSIONER & PULLEY (Continued)
(3) Install timing belt on crankshaft hub, fix it
with VM1074, then around high pressure injection
pump, idler pulley, intake camshaft gear, exhaust
camshaft gear, idler pulley and water pump gear.
NOTE: To uniform the belt tension, slightly rotate
the intake camshaft pulley counterclockwise with
VM 1055.
(4) Adjust the timing belt tensioner (turn it clock-
wise), lining up the tensioner center notch with alu-
minum cover dowel pin (Fig. 114). Tighten the
tensioner bolt to 28N·m (20.5 lbs. ft.).
(5) Torque camshaft gear bolts to 60 N·m (44
lbs.ft.) (pre setting) holding gears with VM 1055.
(6) Remove both camshaft alignment pins from cyl-
inder head cover/intake manifold. (Refer to 9 -
ENGINE/VALVE TIMING - STANDARD PROCE-
DURE) .
(7) Torque camshaft gear bolts to 108 N·m (80
lbs.ft.) while holding gears with VM 1055.
(8) Remove 90° ATDC engine locking pin from
engine block.
CAUTION: Wait 30 minutes before rotating crank-
shaft after installing camshaft cover.
(9) Rotate crankshaft 2 times (looking at it from
the belt side)
(10) Carefully line up the painted mark on the
crankshaft hub and oil pump cover.
CAUTION: IF THE CAMSHAFT ALIGNMENT PINS
CAN NOT BE INSTALLED, REPEAT THIS PROCE-
DURE.
(11) Check that the intake and exhaust cam align-
ment pins CAN be installed, if so remove them.
(12) Install the intake and exhaust camshaft
plugs.
(13) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(14) Install
vibration
damper
(Refer
to
9
-
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
(15) Install the alternator.
(16) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
INSTALLATION).
(17) Install power steering belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
INSTALLATION).
(18) Install right engine mount.
(19) Install air cleaner housing.
(20) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(21) Connect negative battery cable.
Fig. 113 INJECTION PUMP GEAR TIMING MARKS
1 - TIMING MARK ON COVER
2 - TIMING MARK ON INJECTION PUMP SPROCKET
3 - INJECTION PUMP SPROCKET
Fig. 114 TIMING BELT TENSIONER ALIGNMENT
1 - TENSIONER SPRING
2 - 1MM ALIGNMENT POINTER OVERLAP
3 - TENSIONER ALIGNMENT POINTER
4 - TENSIONER ASSEMBLY
RG
ENGINE
9 - 75
TIMING BELT AND SPROCKETS (Continued)
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