Dodge Neon / Neon SRT-4. Manual — part 266

REAR COVER

(1) Remove front timing belt covers. Refer to above

procedures.

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

VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).

(3) Remove timing belt idler pulley (Fig. 129).

(4) Remove camshaft sprockets. Use Special Tool

6847 to hold camshaft sprockets while removing the
sprocket bolts (Fig. 130).

(5) Remove rear timing belt cover fasteners and

remove cover from engine (Fig. 131).

Fig. 129 Timing Belt Idler Pulley

1 - IDLER PULLEY
2 - BOLT

Fig. 130 Camshaft Sprocket—Removal/Installation

1 - SPECIAL TOOL 6847

Fig. 131 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 - 158

ENGINE 2.4L DOHC TURBO

PL/SRT-4

TIMING BELT COVER(S) (Continued)

INSTALLATION

FRONT COVER—UPPER

(1)

Install timing belt cover and tighten fasteners

to 6 N·m (50 in. lbs.) (Fig. 127).

(2) Install torque strut bracket to engine (Fig.

126).

(3) Install torque strut bracket to strut tower (Fig.

126).

(4) Install upper torque strut attaching bolts (Fig.

126).

(5) Perform torque strut adjustment procedure

(Refer

to

9

-

ENGINE/ENGINE

MOUNTING/

TORQUE STRUT - ADJUSTMENTS).

FRONT COVER—LOWER

(1) Install lower timing belt cover and tighten fas-

teners to 6 N·m (50 in. lbs.) (Fig. 127).

(2) Install

engine

support

bracket

(Fig.

128).

Ensure the power steering pump is properly located
in mounting location on bracket. Tighten mount
bracket bolts to 61 N·m (45 ft. lbs.).

(3) Lower

engine

into

mounting

position

and

install right engine mount through bolt. Tighten bolt
to 118 N·m (87 ft. lbs.).

(4) Install power steering pump and bracket.
(5) Install upper torque strut attaching bolts (Fig.

126).

(6) Raise vehicle.
(7) Connect exhaust system to manifold.
(8) Connect A/C pressure switch connector.
(9) Install

crankshaft

damper

(Refer

to

9

-

ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).

(10) Install accessory drive belts (Refer to 7 -

COOLING/ACCESSORY

DRIVE/DRIVE

BELTS

-

INSTALLATION).

(11) Install lower torque strut (Refer to 9 -

ENGINE/ENGINE MOUNTING/TORQUE STRUT -
INSTALLATION).

(12) Perform torque strut adjustment procedure

(Refer

to

9

-

ENGINE/ENGINE

MOUNTING/

TORQUE STRUT - ADJUSTMENTS).

(13) Install acessory drive belt splash shield.
(14) Install right front wheel.
(15) Connect negative cable to battery.

REAR COVER

(1) Install rear timing belt cover and fasteners.

Torque fasteners to values specified in (Fig. 131).

(2) Install timing belt idler pulley (Fig. 129).

Torque timing belt idler pulley fastener 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.

(3) Install camshaft sprockets. Hold sprockets with

Special Tool 6847 while tightening center bolt to 115
N·m (85 ft. lbs.) (Fig. 130).

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

VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).

(5) Install front timing belt covers. Refer to above

procedures.

TIMING BELT AND
SPROCKETS

REMOVAL

TIMING BELT

(1) Disconnect negative battery cable.
(2) Remove upper and lower front timing belt cov-

ers (Fig. 127). (Refer to 9 - ENGINE/VALVE TIM-
ING/TIMING BELT COVER(S) - REMOVAL).

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.

(3) 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. 132).

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.

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

133).

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

opening located on the top plate of the belt tensioner
pulley (Fig. 133). Rotate the top plate CLOCKWISE
until there is enough slack in timing belt to allow for
removal.

(6) Remove timing belt.

PL/SRT-4

ENGINE 2.4L DOHC TURBO

9 - 159

TIMING BELT COVER(S) (Continued)

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).

CAMSHAFT SPROCKET(S)

(1) Remove upper and lower front timing belt cov-

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

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

VALVE TIMING/TIMING BELT - REMOVAL).

(3) Use Special Tool 6847 to hold camshaft sprock-

ets while removing the sprocket bolt(s) (Fig. 134).
Remove camshaft sprocket(s).

Fig. 132 Crankshaft and Camshaft Timing

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

Fig. 133 Timing Belt Tensioner

1 - LOCK BOLT
2 - TOP PLATE

Fig. 134 Camshaft Sprocket—Removal/Installation

1 - SPECIAL TOOL 6847

9 - 160

ENGINE 2.4L DOHC TURBO

PL/SRT-4

TIMING BELT AND SPROCKETS (Continued)

CRANKSHAFT SPROCKET

(1) Remove upper and lower front timing belt cov-

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

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

VALVE TIMING/TIMING BELT - REMOVAL).

(3) Remove crankshaft sprocket using Special Tool

6793 and insert C-4685-C2 (Fig. 135).

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. 136).

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

VALVE TIMING/TIMING BELT - INSTALLATION).

(3) Install upper and lower front timing belt covers

(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT COVER(S) - INSTALLATION).

CAMSHAFT SPROCKET(S)

CAUTION: Do not use an impact wrench to tighten
camshaft sprocket bolts. Damage to the camshaft-
to-sprocket locating dowel pin may occur.

(1) Install camshaft sprockets. Hold sprockets with

Special Tool 6847 while tightening center bolt to 115
N·m (85 ft. lbs.) (Fig. 134).

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

VALVE TIMING/TIMING BELT - INSTALLATION).

(3) Install upper and lower front timing belt covers

(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT COVER(S) - 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. 137).

CAUTION: Ensure that the arrows on both camshaft
sprockets are facing up.

Fig. 135 Crankshaft Sprocket - Removal

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

Fig. 136 Crankshaft Sprocket - Installation

1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL

Fig. 137 Camshaft Sprocket Alignment For Timing

Belt Installation

1 - CAMSHAFT SPROCKET-EXHAUST
2 - CAMSHAFT SPROCKET-INTAKE
3 - 1/2 NOTCH LOCATION

PL/SRT-4

ENGINE 2.4L DOHC TURBO

9 - 161

TIMING BELT AND SPROCKETS (Continued)