Chrysler RG Voyager. Manual — part 940
INSTALLATION - CAMSHAFT SPROCKETS
(1) Install
camshaft
sprockets.
Hold
camshaft
sprockets with Special Tool 6847 while tightening
center bolts to 115 N·m (85 ft. lbs.) (Fig. 120).
(2) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
(3) Connect negative battery cable.
INSTALLATION - TIMING BELT
(1) Set crankshaft sprocket to TDC by aligning the
sprocket with the arrow on the oil pump housing.
(2) Set
camshafts
timing
marks
so
that
the
exhaust camshaft sprocket is a 1/2 notch below the
intake camshaft sprocket (Fig. 123).
CAUTION: Ensure that the arrows on both camshaft
sprockets are facing up.
(3) Install timing belt. Starting at the crankshaft,
go around the water pump sprocket, idler pulley,
camshaft sprockets and then around the tensioner
(Fig. 124).
(4) Move the exhaust camshaft sprocket counter-
clockwise (Fig. 124) to align marks and take up belt
slack.
(5) Insert a 6 mm Allen wrench into the hexagon
opening located on the top plate of the belt tensioner
pulley. Rotate the top plate COUNTERCLOCK-
WISE. The tensioner pulley will move against the
belt and the tensioner setting notch will eventually
start to move clockwise. Watching the movement of
the setting notch, continue rotating the top plate
counterclockwise until the setting notch is aligned
with the spring tang (Fig. 125). Using the allen
wrench to prevent the top plate from moving, torque
the tensioner lock bolt to 25 N·m (220 in. lbs.). Set-
ting notch and spring tang should remain aligned
after lock nut is torqued.
(6) Remove allen wrench and torque wrench.
NOTE: Repositioning the crankshaft to the TDC
position must be done only during the CLOCKWISE
rotation movement. If TDC is missed, rotate a fur-
ther two revolutions until TDC is achieved. DO NOT
rotate crankshaft counterclockwise as this will
make verification of proper tensioner setting impos-
sible.
(7) Rotate the crankshaft CLOCKWISE two com-
plete revolutions manually for seating of the belt,
until the crankshaft is repositioned at the TDC posi-
tion. Verify that the camshaft and crankshaft timing
marks are in proper position (Fig. 126).
(8) Check if the spring tang is within the tolerance
window (Fig. 127). If the spring tang is within the
tolerance window, the installation process is complete
Fig. 123 Camshaft Sprocket Alignment
1 - CAMSHAFT SPROCKET-EXHAUST
2 - CAMSHAFT SPROCKET-INTAKE
3 - 1/2 NOTCH LOCATION
Fig. 124 Timing Belt Installation
1 - CAMSHAFT TIMING MARKS 1/2 NOTCH LOCATION
2 - CRANKSHAFT AT TDC
3 - INSTALL BELT IN THIS DIRECTION
4 - ROTATE CAMSHAFT SPROCKET TO TAKE UP BELT SLACK
RS
ENGINE 2.4L
9 - 69
TIMING BELT AND SPROCKET(S) (Continued)
and nothing further is required. If the spring tang is
not within the tolerance window, repeat Steps 5
through 7.
(9) Install engine mount bracket to engine (Fig.
117).
(10) Install timing belt front covers and bolts
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT COVER(S) - INSTALLATION).
(11) Install air conditioning/generator belt ten-
sioner and pulley (Refer to 7 - COOLING/ACCES-
SORY
DRIVE/BELT
TENSIONERS
-
INSTALLATION).
(12) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(13) Install crankshaft vibration damper (Refer to
9
-
ENGINE/ENGINE
BLOCK/VIBRATION
DAMPER - INSTALLATION).
(14) Install accessory drive belts (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
INSTALLATION).
(15) Install drive belt splash shield.
(16) Install right front wheel.
(17) Connect make-up air hose to cylinder head
cover.
(18) Install air cleaner housing, upper cover, and
clean air tube.
Fig. 125 Timing Belt Tension Adjustment
1 - ALIGN SETTING NOTCH WITH SPRING TANG
2 - TOP PLATE
3 - 6mm ALLEN WRENCH
4 - LOCK BOLT
5 - SETTING NOTCH
6 - SPRING TANG
Fig. 126 Crankshaft and Camshaft Timing
1 - CAMSHAFT TIMING MARKS
2 - CRANKSHAFT TDC MARKS
3 - TRAILING EDGE OF SPROCKET TOOTH
Fig. 127 Timing Belt Tension Verification
1 - SPRING TANG
2 - TOLERANCE WINDOW
9 - 70
ENGINE 2.4L
RS
TIMING BELT AND SPROCKET(S) (Continued)
TIMING BELT TENSIONER &
PULLEY
REMOVAL
(1) Remove the timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(2) Remove timing belt idler pulley (Fig. 128).
(3) Hold camshaft sprocket with Special Tool 6847
while removing bolt (Fig. 129). Remove both cam
sprockets.
(4) Remove rear timing belt cover fasteners and
remove cover from engine (Fig. 130).
(5) Remove lower bolt attaching timing belt ten-
sioner assembly to engine and remove tensioner as
an assembly (Fig. 131).
INSTALLATION
(1) Align timing belt tensioner assembly to engine
and install lower mounting bolt but do not tighten
(Fig. 131). To properly align tensioner assembly—in-
stall one of the engine bracket mounting bolts (M10)
5 to 7 turns into the tensioner’s upper mounting loca-
tion (Fig. 131).
(2) Torque the tensioner’s lower mounting bolt to
61 N·m (45 ft. lbs.). Remove the upper bolt used for
tensioner alignment.
(3) Install rear timing belt cover and fasteners.
Torque fasteners to values specified in (Fig. 130).
(4) Install timing belt idler pulley and torque
mounting bolt to 61 N·m (45 ft. lbs.) (Fig. 128).
(5) Install camshaft sprockets. Use Special Tool
6847 to hold sprockets (Fig. 129), torque bolts to 101
N·m (75 ft. lbs.).
Fig. 128 Timing Belt Idler Pulley
1 - IDLER PULLEY
2 - BOLT
Fig. 129 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 130 Rear Timing Belt Cover Fasteners
1 - M6 BOLTS - 12 N·m (105 in. lbs.)
2 - M8 BOLTS - 28 N·m (250 in. lbs.)
3 - TIMING BELT TENSIONER
RS
ENGINE 2.4L
9 - 71
(6) Install the timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
BALANCE SHAFTS AND
CARRIER ASSEMBLY
DESCRIPTION
The 2.4L engine is equipped with two nodular cast
iron balance shafts installed in a cast aluminum car-
rier attached to the lower cylinder block (Fig. 132).
OPERATION
The balance shafts are driven by the crankshaft
via a roller chain and sprockets. The balance shafts
are connected by helical gears. The dual counter
rotating shafts decrease second order vertical shak-
ing forces caused by component movement.
REMOVAL
BALANCE SHAFTS/CHAIN/SPROCKETS
NOTE: For service procedures requiring only tem-
porary relocation of carrier assembly refer to BAL-
ANCE SHAFT CARRIER procedure below.
(1) Drain engine oil.
(2) Remove the oil pan and pick-up tube (Refer to
9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL).
(3) If replacing crankshaft sprocket, remove oil
pump (Refer to 9 - ENGINE/LUBRICATION/OIL
PUMP - REMOVAL).
(4) Remove chain cover, guide and tensioner. Dis-
card pivot screw and adjuster screw. (Fig. 133).
(5) Remove screw retaining balance shaft drive
sprocket (Fig. 134). Remove chain and sprocket.
(6) Using two wide pry bars, work the crankshaft
sprocket back and forth until it is off the crankshaft-
shaft.
Fig. 131 Timing Belt Tensioner/Bracket Assembly
1 - BOLT
2 - TENSIONER ASSEMBLY
3 - BOLT-INSTALL FOR PROPER ALIGNMENT
9 - 72
ENGINE 2.4L
RS
TIMING BELT TENSIONER & PULLEY (Continued)
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