Dodge Neon / Neon SRT-4. Manual — part 267
(3) Install timing belt. Starting at the crankshaft,
go around the water pump sprocket, idler pulley,
camshaft sprockets and then around the tensioner
(Fig. 138).
(4) Move the exhaust camshaft sprocket counter-
clockwise (Fig. 138) 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. 139). 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 bolt is torqued.
(6) Remove allen wrench and torque wrench.
Fig. 138 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
Fig. 139 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
9 - 162
ENGINE 2.4L DOHC TURBO
PL/SRT-4
TIMING BELT AND SPROCKETS (Continued)
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. 140).
(8) Check if the spring tang is within the tolerance
window (Fig. 141). If the spring tang is within the
tolerance window, the installation process is complete
and nothing further is required. If the spring tang is
not within the tolerance window, repeat Steps 5
through 7.
(9) Install upper and lower front timing belt covers
(Fig. 127). (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT COVER(S) - INSTALLATION).
(10) Connect negative cable to battery.
TIMING BELT TENSIONER &
PULLEY
REMOVAL
(1) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(2) Remove timing belt idler pulley.
(3) Hold camshaft sprocket with Special Tool 6847
while removing bolt (Fig. 142). Remove both cam-
shaft sprockets.
(4) Remove rear timing belt cover fasteners and
remove cover from engine (Fig. 143).
(5) Remove lower bolt attaching timing belt ten-
sioner assembly to engine and remove tensioner as
an assembly (Fig. 144).
INSTALLATION
(1) Align timing belt tensioner assembly to engine
and install lower mounting bolt but do not tighten
(Fig. 144). To properly align tensioner assembly to
engine; temporarily install one of the engine bracket
mounting bolts (M10) 5–7 turns into the tensioner
assembly upper mounting location (Fig. 144).
(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
(Fig. 143).
Fig. 140 Crankshaft and Camshaft Timing
1 - CAMSHAFT TIMING MARKS
2 - CRANKSHAFT TDC MARKS
3 - TRAILING EDGE OF SPROCKET TOOTH
Fig. 141 Timing Belt Tension Verification
1 - SPRING TANG
2 - TOLERANCE WINDOW
PL/SRT-4
ENGINE 2.4L DOHC TURBO
9 - 163
TIMING BELT AND SPROCKETS (Continued)
(4) Install timing belt idler pulley and torque
mounting bolt to 61 N·m (45 ft. lbs.).
CAUTION: Do not use an impact wrench to tighten
camshaft sprocket bolts. Damage to the camshaft-
to-sprocket locating dowel pin may occur.
(5) Install camshaft sprockets. Use Special Tool
6847 to hold sprockets (Fig. 142) and tighten bolts to
115 N·m (85 ft. lbs.).
(6) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
Fig. 142 Camshaft Sprockets
1 - SPECIAL TOOL 6847
Fig. 143 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
Fig. 144 Timing Belt Tensioner/Bracket Assembly
1 - BOLT
2 - TENSIONER ASSEMBLY
3 - BOLT-INSTALL FOR PROPER ALIGNMENT
9 - 164
ENGINE 2.4L DOHC TURBO
PL/SRT-4
TIMING BELT TENSIONER & PULLEY (Continued)
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. 145).
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. 146).
(5) Remove screw retaining balance shaft drive
sprocket (Fig. 147). Remove chain and sprocket.
(6) Using two wide pry bars, work the crankshaft
sprocket back and forth until it is off the crankshaft-
shaft.
(7) Remove gear cover retaining stud (double
ended to also retain chain guide). Remove cover and
balance shaft gears (Fig. 148).
(8) Remove rear cover and balance shafts (Fig.
149).
(9) Remove four carrier to crankcase attaching
bolts to separate carrier from engine bedplate.
BALANCE SHAFT CARRIER
The following components will remain intact dur-
ing carrier removal: Gear cover, gears, balance shafts
and the rear cover (Fig. 145).
(1) Drain engine oil.
(2) Remove the oil pan and pick-up tube (Refer to
9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL).
(3) Remove chain cover, guide and tensioner (Fig.
146).
Fig. 145 Balance Shafts and Carrier Assembly
1 - SPROCKET
7 - GEARS
2 - TENSIONER
8 - GEAR COVER
3 - PLUG
9 - CHAIN COVER
4 - CARRIER
10 - SPROCKET
5 - REAR COVER
11 - GUIDE
6 - BALANCE SHAFTS
12 - CHAIN
PL/SRT-4
ENGINE 2.4L DOHC TURBO
9 - 165
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