300M, Concorde, Intrepid, LHS, 1998-2004

Timing Belt

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Removal & Installation



2.5L (VIN H) Engine
  1. Disconnect the negative battery cable from the left strut tower. The ground cable is equipped with a insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.
  2.  
  3. Remove the right inner splash-shield.
  4.  
  5. Remove the accessory drive belts.
  6.  
  7. Remove the crankshaft damper.
  8.  
  9. Remove the right engine mount.
  10.  
  11. Place a suitable floor jack under the vehicle to support the engine.
  12.  
  13. Remove the right engine mount bracket.
  14.  
  15. Remove the timing belt upper left cover, upper right cover and lower cover.
  16.  
  17. Loosen the timing belt tensioner bolts.
    NOTE
    Before removing timing belt, be sure to align the sprocket timing marks to the timing marks on the rear timing belt cover.

  18.  
  19. If the present timing belt is going to be reused, mark the running direction of the timing belt for installation. Remove the timing belt and the tensioner.
  20.  
  21. Remove the camshaft timing belt sprockets from the camshaft, if necessary.
  22.  
  23. Remove the crankshaft timing belt sprocket and key.
  24.  
  25. Place the tensioner into a soft-jawed vise to compress the tensioner.
  26.  
  27. After compressing the tensioner place a pin into the plunger side hole to retain the plunger until installation.

    Click image to see an enlarged view

    Fig. Timing belt engine sprocket timing-2.5L (VIN H) Engine

  28.  

To install:

  1. If removed, reinstall the camshaft sprockets onto the camshaft. Install the camshaft sprocket bolt and tighten to 65 ft. lbs. (88 Nm).
  2.  
  3. If removed, reinstall the crankshaft timing belt sprocket and key onto the crankshaft.
  4.  
  5. Set the crankshaft sprocket to Top Dead Center (TDC) by aligning the notch on the sprocket with the arrow on the oil pump housing, then back off the sprocket three notches before TDC.
  6.  
  7. Set the camshafts to align the timing marks on the sprockets with the marks on the rear timing belt cover.
  8.  
  9. Install the belt on the rear camshaft sprocket first.
  10.  
  11. Install a binder clip on the belt to the sprocket so it won't slip out of position.
  12.  
  13. Keeping the belt taut, install it under the water pump pulley and around the front camshaft sprocket.
  14.  
  15. Install a binder on the front sprocket and belt.
  16.  
  17. Rotate the crankshaft to TDC.
  18.  
  19. Continue routing the belt by the idler pulley and around the crankshaft sprocket to the tensioner pulley.
  20.  
  21. Move the crankshaft sprocket clockwise to TDC to take up the belt slack. Check that all timing marks are in alignment.
  22.  
  23. Reinstall the tensioner to the block but do not tighten it at this time.
  24.  
  25. Using special tool No. MD998767 and a torque wrench on the tensioner pulley, apply 39 inch lbs. (4.4 Nm) of torque to the tensioner. Tighten the tensioner pulley bolt to 35 ft. lbs. (48 Nm).
  26.  
  27. With torque being applied to the tensioner pulley, move the tensioner up against the tensioner bracket and tighten the fasteners to 17 ft. lbs. (23 Nm).
  28.  
  29. Remove the tensioner plunger pin, the tension is correct when the plunger pin can be removed and replaced easily.
  30.  
  31. Rotate the crankshaft two revolutions clockwise and recheck the timing marks. Check to be sure the tensioner plunger pin can be easily installed and removed. If the pin does not remove and install easily, perform the procedure again.
  32.  
  33. Reinstall the timing belt cover.
  34.  
  35. Reinstall the engine mount bracket.
  36.  
  37. Reinstall the right engine mount.
  38.  
  39. Remove the engine support.
  40.  
  41. Install the crankshaft damper and tighten to 134 ft. lbs. (182 Nm).
  42.  
  43. Reinstall the accessory drive belts and adjust them.
  44.  
  45. Reinstall the right inner splash-shield.
  46.  
  47. Perform the crankshaft and camshaft relearn alignment procedure using the DRB scan tool or equivalent.
  48.  

2.5L (VIN N) Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the accessory drive belts.
  4.  
  5. Using Crankshaft Holding Tools MB990767 and MB998754, remove the crankshaft bolt and remove the pulley.
  6.  
  7. Remove the heated oxygen sensor connection.
  8.  
  9. Remove the power steering pump with the hose attached and position it aside.
  10.  
  11. Remove the power steering pump bracket.
  12.  
  13. Place a floor jack under the engine oil pan, with a block of wood in between, and raise the engine so that the weight of the engine is no longer being applied to the engine support bracket.
  14.  
  15. Remove the upper engine mount. Spraying lubricant, slowly remove the reamer (alignment) bolt and remaining bolts and remove the engine support bracket.
    NOTE
    The reamer bolt is sometimes heat-seized on the engine support bracket.

  16.  
  17. Remove the front timing belt covers.
  18.  
  19. If the timing belt is to be reused, draw an arrow indicating the direction of rotation on the back of the belt for reinstallation.
  20.  
  21. Align the timing marks by turning the crankshaft with MD998769 Crankshaft Turning tool. Loosen the center bolt on the timing belt tensioner pulley and remove the belt.
    WARNING
    Do not rotate the crankshaft or camshaft after removing the timing belt or valvetrain components may be damaged. Always align the timing marks before removing the timing belt.

  22.  
  23. Check the belt tensioner for leaks and check the pushrod for cracks.
  24.  
  25. If the timing belt tensioner is to be replaced, remove the retaining bolts and remove the timing belt tensioner. When the timing belt tensioner is removed from the engine, it is necessary to compress the plunger into the tensioner body.
  26.  
  27. Place the tensioner in a vise and slowly compress the plunger. Take care not to damage the pushrod.
    NOTE
    Position the tensioner in the vise the same way it will be installed on the engine. This is to ensure proper pin orientation for when the tensioner is installed on the engine.

  28.  
  29. When the plunger is compressed into the tensioner body, install a pin through the body and plunger to hold the plunger in place until the tensioner is installed.

    Click image to see an enlarged view

    Fig. Camshaft and crankshaft alignment marks-Chrysler 2.5L (VIN N) engines

  30.  

To install:

  1. Install the timing belt tensioner and tighten the retaining bolts to 17 ft. lbs. (24 Nm), but do not remove the pin at this time.
  2.  
  3. Check that all timing marks are still aligned.
  4.  
  5. Use bulldog clips (large paper binder clips) or other suitable tool to secure the timing belt and to prevent it from slacking. Install the timing belt. Starting at the crankshaft, go around the idler pulley, then the front camshaft sprocket, the water pump pulley, the rear camshaft sprocket and the tensioner pulley.
  6.  
  7. Be sure the belt is tight between the crankshaft and front camshaft sprocket, between the camshaft sprockets and the water pump. Gently raise the tensioner pulley, so that the belt does not sag, and temporarily tighten the center bolt.
  8.  
  9. Move the crankshaft 1 / 4 turn counterclockwise, then turn it clockwise to the position where the timing marks are aligned.
  10.  
  11. Loosen the center bolt of the tensioner pulley. Using MD998767 tensioner tool, and a torque wrench apply 3.3 ft. lbs. (4.4 Nm) tensional torque to the timing belt and tighten the center bolt to 35 ft. lbs. (48 Nm). When tightening the bolt, be sure that the tensioner pulley shaft does not rotate with the bolt.
  12.  
  13. Remove the tensioner plunger pin. Pretension is correct when the pin can be removed and installed easily. If the pin cannot be easily removed and installed it is still satisfactory as long as it is within its standard value.
  14.  
  15. Check that the tensioner pushrod is within the standard value. When the tensioner is engaged the pushrod should measure 0.149-0.177 in. (3.8-4.5mm).
  16.  
  17. Rotate the crankshaft two revolutions and check the timing marks. If the timing marks are not properly aligned remove the belt and repeat Steps 17 through 23.
  18.  
  19. Install the timing belt covers.
  20.  
  21. Install the engine mounting bracket.
  22.  
  23. Lower the engine enough to install the engine mount onto bracket and remove the floor jack.
  24.  
  25. Install the power steering pump bracket and pump.
  26.  
  27. Install the crankshaft pulley and tighten the retaining bolt to 13 ft. lbs. (18 Nm).
  28.  
  29. Install the accessory drive belts.
  30.  
  31. Properly fill the cooling system.
  32.  
  33. Connect the negative battery cable.
  34.  
  35. Check for leaks and proper engine and cooling system operation.
  36.  

3.2L (VIN J) And 3.5L (VIN F) Engines

Use care when servicing a timing belt. Valve timing is absolutely critical to engine performance. If the valve timing marks on all drive sprockets are not properly aligned, engine damage will result. If only the belt and tensioner are being serviced, do not loosen the camshaft drive sprockets unless they are to be replaced. The sprockets have oversized openings and can be rotated several degrees in each direction on their shafts. This means the sprockets must be retimed, requiring some special tools.


CAUTION
Fuel injection systems remain under pressure, even after the engine has been turned off. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Disconnect the negative battery cable.
  2.  
  3. Rotate the engine to Top Dead Center (TDC) on the compression stroke for cylinder No. 1.
  4.  
  5. Release the fuel system pressure using the recommended procedure.
  6.  
  7. Place a pan under the radiator and drain the coolant.
  8.  
  9. Remove the radiator and cooling fan assemblies.
  10.  
  11. Remove the accessory drive belts.
  12.  
  13. Remove the upper radiator hose.
  14.  
  15. Remove the crankshaft damper with a quality puller tool gripping the inside of the pulley.
  16.  
  17. Remove the stamped steel cover. Do not remove the sealer on the cover; it may be reusable.
  18.  
  19. Remove the left side cast cover. If necessary, remove the lower belt cover, located behind the crankshaft damper.
  20.  
  21. If the timing belt is to be reused, mark the timing belt with the running direction for installation.
  22.  
  23. Align the camshaft sprockets with the marks on the rear covers.
  24.  
  25. Remove the timing belt and tensioner.
  26.  
  27. If it is necessary to service the camshaft sprockets, use the following procedure:
    1. Hold the camshaft sprocket with a 36mm box end wrench, loosen and remove the sprocket retaining bolt and washer.
      NOTE
      To remove the camshaft sprocket retainer bolt while the engine is in the vehicle, it may be necessary to raise that side of the engine due to the length of the retainer bolt. The right bolt is 8 3 / 8 in. (213mm) long, while the left bolt is 10 in. (254mm) long. These bolts are not interchangeable and their original location during removal should be noted.

    2.  
    3. Remove the camshaft sprocket from the camshaft. The camshaft sprockets are not interchangeable from side-to-side.
    4.  
    5. Remove the crankshaft sprocket using Puller L-4407A.

      Click image to see an enlarged view

      Fig. Timing belt alignment marks-Chrysler 3.2L and 3.5L engines

    6.  

  28.  

To install:

  1. If it was necessary to remove the camshaft sprockets, use the following procedure:
    NOTE
    This procedure can only be used when the camshaft sprockets have been loosened or removed from the camshafts. Each sprocket has a D shaped hole that allows it to be rotated several degrees in each direction on its shaft. This design must be timed with the engine to ensure proper performance.

    1. Install the crankshaft sprocket, using tool C-4685-C1, thrust bearing, washer and 12mm bolt.
    2.  
    3. When the camshaft sprockets are loosened or removed, the camshafts must be timed to the engine. Install the Camshaft Alignment tools 6642-A, to the rear of the cylinder heads. These tools lock the camshafts in the proper position.
    4.  

  2.  
  3. Preload the belt tensioner as follows:
    1. Place the tensioner in a vise the same way it is mounted on the engine.
    2.  
    3. Slowly compress the plunger into the tensioner body.
    4.  
    5. When the plunger is compressed into the tensioner body, install a pin through the body and plunger to retain the plunger in place until the tensioner is installed.
    6.  

  4.  
  5. Install both camshaft sprockets to the appropriate shafts. The left camshaft sprocket has the Distributorless Ignition System (DIS) pick-up as part of the sprocket.
    NOTE
    The right bolt is 8 3 / 8 in. (213mm) long, while the left bolt is 10 in. (254mm) long. These bolts are not interchangeable.

  6.  
  7. Apply Loctite®271, to the threads of the camshaft sprocket retainer bolts and install to the appropriate shafts. Do not tighten the bolts at this time.
  8.  
  9. Align the camshaft sprockets between the marks on the rear belt covers.
  10.  
  11. Align the crankshaft sprocket with the TDC mark on the oil pump cover.
  12.  
  13. Install the timing belt, starting at the crankshaft sprocket and going in a counterclockwise direction. After the belt is installed on the right sprocket, keep tension on the belt until it is past the tensioner pulley.
  14.  
  15. Holding the tensioner pulley against the belt, install the timing belt tensioner into the housing and tighten to 21 ft. lbs. (28 Nm).
  16.  
  17. When the tensioner is in place, pull the retainer pin out to allow tensioner to extend to the pulley bracket.
    NOTE
    Be sure that the timing marks on the cam sprockets are still between the marks on the rear cover.

  18.  
  19. Remove the spark plug in the No.1 cylinder and install a dial indicator to check for TDC of the piston. Rotate the crankshaft until the piston is exactly at TDC.
  20.  
  21. Hold the camshaft sprocket hex with a 36mm wrench and tighten the right camshaft sprocket bolt to 75 ft. lbs. (102 Nm) plus an additional 90 degree turn. Tighten the left camshaft sprocket bolt to 85 ft. lbs. (115 Nm) plus an additional 90 degree turn.
  22.  
  23. Remove the dial indicator. Install the spark plug and tighten to 20 ft. lbs. (28 Nm).
  24.  
  25. Remove the camshaft alignment tools from the back of the cylinder heads and install the cam covers with new O-rings.
  26.  
  27. Tighten the fasteners to 20 ft. lbs. (27 Nm). Repeat this procedure on the other camshaft.
  28.  
  29. Rotate the crankshaft sprocket two revolutions and check for proper alignment of the timing marks on the camshaft and the crankshaft. If the timing marks do not align, repeat the procedure.
  30.  
  31. Before installing, inspect the sealer on the stamped steel cover. If some sealer is missing, use MOPAR Silicone Rubber Adhesive sealant to replace the missing sealer.
  32.  
  33. Install the lower belt cover behind the crankshaft damper, if necessary.
  34.  
  35. Install the stamped steel cover and the left side cast cover. Tighten the 6mm bolts to 105 inch lbs. (12 Nm), the 8mm bolts to 250 inch lbs. (28 Nm) and the 10mm bolts to 40 ft. lbs. (54 Nm).
  36.  
  37. Install the crankshaft damper using special tool L-4524, a 5.9 in. long bolt, thrust bearing and washer. Tighten the center bolt to 85 ft. lbs. (115 Nm).
  38.  
  39. Install the upper radiator hose.
  40.  
  41. Install the accessory drive belts and adjust them to the proper tension.
  42.  
  43. Install the radiator and cooling fan assemblies.
  44.  
  45. Refill and bleed the cooling system.
  46.  
  47. Connect the negative battery cable.
  48.  
  49. With the radiator cap off so coolant can be added, run the engine. Watch for leaks and listen for unusual engine noises.
  50.  

 
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