Chrysler RG Voyager. Manual — part 939

(3) Remove timing belt (Refer to 9 - ENGINE/

VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).

(4) Remove camshaft sprockets. Hold camshaft

sprocket with Special Tool 6847 while removing cen-
ter bolt (Fig. 114).

(5) Remove timing belt idler pulley (Fig. 115).
(6) Remove rear cover fasteners and remove cover

from engine (Fig. 116).

Fig. 113 Engine Mount Bracket

1 - ENGINE MOUNT BRACKET
2 - BOLTS - 61 N·m (45 ft. lbs.)

Fig. 114 Camshaft Sprocket - Removal/Installation

1 - SPECIAL TOOL 6847

Fig. 115 Timing Belt Idler Pulley

1 - IDLER PULLEY
2 - BOLT

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ENGINE 2.4L

9 - 65

TIMING BELT COVER(S) (Continued)

INSTALLATION

FRONT COVER - UPPER

(1) Install timing belt cover. Torque fasteners to 6

N·m (50 in. lbs.) (Fig. 112).

FRONT COVER - LOWER

(1) Install timing belt front covers (Fig. 112).

Tighten fasteners to 6 N·m (50 in. lbs.).

(2) Install generator drive belt tensioner (Refer to

7

-

COOLING/ACCESSORY

DRIVE/BELT

TEN-

SIONERS - INSTALLATION).

(3) Install crankshaft vibration damper (Refer to 9

- ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).

REAR COVER

(1) Install rear timing belt cover and fasteners.

Torque fasteners to specified values (Fig. 116).

CAUTION: Do not use an impact wrench for tighten-
ing camshaft sprocket bolt. Damage to the timing
locating pin can occur. Hand tighten using a
wrench ONLY.

(2) Install camshaft sprockets. Hold sprockets with

Special Tool 6848 and tighten center bolt to 101 N·m
(75 ft. lbs.) (Fig. 114).

(3) Install timing belt idler pulley and tighten

mounting bolt to 61 N·m (45 ft. lbs.) (Fig. 115).

(4) Install timing belt (Refer to 9 - ENGINE/

VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).

(5) Install engine mount bracket and tighten bolts

to 61 N·m (45 ft. lbs.) (Fig. 113).

(6) Install front covers.

TIMING BELT AND
SPROCKET(S)

REMOVAL

REMOVAL - TIMING BELT

(1) Remove air cleaner upper cover, housing, and

clean air tube.

(2) Remove make-up air hose from cylinder head

cover.

(3) Raise vehicle on hoist.
(4) Remove right front wheel.
(5) Remove right inner splash shield.
(6) Remove accessory drive belts (Refer to 7 -

COOLING/ACCESSORY

DRIVE/DRIVE

BELTS

-

REMOVAL).

(7) Remove crankshaft vibration damper (Refer to

9

-

ENGINE/ENGINE

BLOCK/VIBRATION

DAMPER - REMOVAL).

(8) Remove air conditioner/generator belt tensioner

and pulley assembly (Refer to 7 - COOLING/ACCES-
SORY DRIVE/BELT TENSIONERS - REMOVAL).

(9) Remove timing belt lower front cover bolts and

remove cover (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT COVER(S) - REMOVAL).

(10) Lower vehicle.
(11) Remove bolts attaching timing belt upper

front cover and remove cover (Refer to 9 - ENGINE/
VALVE

TIMING/TIMING

BELT

COVER(S)

-

REMOVAL).

(12)

Remove right engine mount (Refer to 9 -

ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
REMOVAL).

(13) Remove engine mount bracket (Fig. 117).

Fig. 116 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

9 - 66

ENGINE 2.4L

RS

TIMING BELT COVER(S) (Continued)

CAUTION: When aligning crankshaft and camshaft
timing marks always rotate engine from crankshaft.
Camshaft should not be rotated after timing belt is
removed. Damage to valve components may occur.
Always align timing marks before removing timing
belt.

(14) Before the removal of the timing belt, rotate

crankshaft until the TDC mark on oil pump housing
aligns with the TDC mark on crankshaft sprocket
(trailing edge of sprocket tooth) (Fig. 118).

NOTE:

The

crankshaft

sprocket

TDC

mark

is

located on the trailing edge of the sprocket tooth.
Failure to align trailing edge of sprocket tooth to
TDC mark on oil pump housing will cause the cam-
shaft timing marks to be misaligned.

(15) Loosen timing belt tensioner lock bolt (Fig.

119).

(16) Insert a 6 mm Allen wrench into the hexagon

opening located on the top plate of the belt tensioner
pulley (Fig. 119). Rotate the top plate CLOCKWISE
until there is enough slack in timing belt to allow for
removal.

(17) Remove timing belt.

CAUTION: If timing belt was damaged due to incor-
rect tracking (alignment), the belt tensioner pulley
and bracket must be replaced as an assembly
(Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT
TENSIONER & PULLEY - REMOVAL).

REMOVAL - CAMSHAFT SPROCKETS

(1) Disconnect negative battery cable.
(2) Remove timing belt (Refer to 9 - ENGINE/

VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).

(3) Hold camshaft sprockets with Special Tool 6847

while removing center bolts (Fig. 120).

REMOVAL - CRANKSHAFT SPROCKET

(1) Disconnect negative battery cable.
(2) Remove timing belt (Refer to 9 - ENGINE/

VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).

(3) Remove

crankshaft

sprocket

using

Special

Tools 6793 and insert C-4685-C2 (Fig. 121).

Fig. 117 Engine Mount Bracket

1 - ENGINE MOUNT BRACKET
2 - BOLTS - 61 N·m (45 ft. lbs.)

Fig. 118 Crankshaft and Camshaft Timing

1 - CAMSHAFT TIMING MARKS
2 - CRANKSHAFT TDC MARKS
3 - TRAILING EDGE OF SPROCKET TOOTH

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ENGINE 2.4L

9 - 67

TIMING BELT AND SPROCKET(S) (Continued)

CLEANING

Do Not attempt to clean a timing belt. If contami-

nation from oil, grease, or coolants have occurred, the
timing belt should be replaced.

Clean all sprockets using a suitable solvent. Clean

all sprocket grooves of any debris.

INSTALLATION

INSTALLATION - CRANKSHAFT SPROCKET

CAUTION: The crankshaft sprocket is set to a pre-
determined depth from the factory for correct tim-
ing belt tracking. If removed, use of Special Tool
6792 is required to set the sprocket to original
installation depth. An incorrectly installed sprocket
will result in timing belt and engine damage.

(1) Install crankshaft sprocket using Special Tool

6792 (Fig. 122).

(2) Install timing belt. (Refer to 9 - ENGINE/

VALVE

TIMING/TIMING

BELT/CHAIN

AND

SPROCKETS - INSTALLATION)

Fig. 119 Timing Belt Tensioner

1 - LOCK BOLT
2 - TOP PLATE

Fig. 120 Camshaft Sprocket - Removal/Installation

1 - SPECIAL TOOL 6847

Fig. 121 Crankshaft Sprocket - Removal

1 - SPECIAL TOOL 6793
2 - SPECIAL TOOL C-4685–C2
3 - CRANKSHAFT SPROCKET

Fig. 122 Crankshaft Sprocket - Installation

1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL

9 - 68

ENGINE 2.4L

RS

TIMING BELT AND SPROCKET(S) (Continued)