Avenger 2008

Timing Belt & Sprockets

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Removal & Installation



3.5L Engine
Camshaft Sprocket

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009


CAUTION
The 3.5L engine is NOT a free-wheeling design. Therefore, care should be taken not to rotate the camshafts or crankshaft with the timing belt removed.


NOTE
The camshaft timing gears are keyed to the camshaft.

  1. Perform fuel pressure release procedure.
  2.  
  3. Remove front timing belt cover.
  4.  
  5. Position crankshaft sprocket to the TDC mark on the oil pump housing by turning crankshaft in the clockwise direction
  6.  
  7. Install a dial indicator in number 1 cylinder to check TDC of the piston. Rotate the crankshaft until the piston is at exactly TDC.
  8.  
  9. Remove camshaft retainer/thrust plate from rear of right cylinder head.

    Click image to see an enlarged view

    Fig. Remove the right rear camshaft thrust plate (1)

  10.  
  11. Remove the cylinder head covers.
  12.  
  13. Remove rocker arm assemblies.
  14.  
  15. Remove the timing belt tensioner and timing belt.
  16.  
  17. Loosen and remove the left camshaft gear retaining bolt and washer. The left bolt is 10.0 inches (255 mm) long.
    NOTE
    The camshaft timing gears are keyed to the camshaft.

  18.  
  19. Hold the left camshaft sprocket with 1 7 / 16 (36 mm) box end wrench.

    Click image to see an enlarged view

    Fig. Hold the left camshaft sprocket with box end wrench

  20.  
  21. Remove the left camshaft sprocket.
    CAUTION
    The right camshaft must be pushed rearward approximately 3 1 / 2 inches to remove the camshaft gear retaining bolt and gear. Care must be taken not to scratch or nick the camshaft or cylinder head journals when moving camshaft.

  22.  
  23. Loosen and remove the right camshaft gear retaining bolt and washer. The right bolt is 8 3 / 8 inches (213 mm) long.
    NOTE
    The camshaft timing gears are keyed to the camshaft.

  24.  
  25. Hold the right camshaft sprocket with 1 7 / 16 (36 mm) box end wrench and loosen the camshaft bolt.

    Click image to see an enlarged view

    Fig. Hold the right camshaft sprocket with box end wrench

  26.  
  27. Using a floor jack, raise the right side of the engine enough to allow clearance to remove the right camshaft bolt and washer.
  28.  
  29. Remove the right camshaft sprocket.
  30.  

To install:


CAUTION
The camshaft sprockets are keyed and not interchangeable from side to side because of the camshaft position sensor pick-up.

  1. Install camshaft sprockets onto the camshafts. Install NEW sprocket attaching bolts into place. The 10.0 inches (255 mm) bolt is installed in the left camshaft and the 8 3 / 8 inches (213 mm) bolt is installed into the right camshaft. Do not tighten the bolts; tightened at later step. Camshaft sprocket mark should be aligned with the marks on the cover at both sprockets.
  2.  
  3. Install the camshaft thrust plates and seals. Tighten bolts to 21 ft. lbs. (28 Nm).
  4.  
  5. Install the timing belt starting first at the crankshaft sprocket, then to remaining components in a counterclockwise direction.

    Click image to see an enlarged view

    Fig. Install the timing belt

  6.  
  7. Install the belt around the last sprocket. Maintain tension on the belt as it is positioned around the tensioner pulley. Each camshaft sprockets mark should still be aligned with the rear cover marks.
    NOTE
    It is necessary to compress the plunger into the tensioner body and install a locking pin prior to reinstalling the tensioner.

  8.  
  9. Hold the tensioner pulley against the belt and install the reset (pinned) timing belt tensioner into the housing. Tighten attaching bolts to 21 ft. lbs. (28 Nm).
  10.  
  11. Remove tensioner retaining pin to allow the tensioner to extend to the pulley bracket.
  12.  
  13. Using a dial indicator, position the number 1 piston at TDC.
  14.  
  15. Hold the right camshaft sprocket hex with a 1 7 / 16 (36 mm) wrench and tighten the right camshaft bolt to 75 ft. lbs. (102 Nm) plus 90° turn.
  16.  
  17. Hold the left camshaft sprocket hex with a 1 7 / 16 (36 mm) wrench and tighten the left camshaft bolts to 75 ft. lbs. (102 Nm) plus 90° turn.
  18.  
  19. Remove dial indicator and install spark plug.
  20.  
  21. Install front timing belt cover.
  22.  

Crankshaft Sprocket

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

  1. Remove the timing belt.
  2.  
  3. Remove crankshaft sprocket using Gear Puller L-4407A (1).

    Click image to see an enlarged view

    Fig. Remove crankshaft sprocket using Gear Puller L-4407A (1)

  4.  

To install:


CAUTION
To ensure proper installation depth of crankshaft sprocket, Sprocket Installer 6641 must be used.

  1. Install crankshaft sprocket using Sprocket Installer 6641 and Forcing Screw C-4685-C1.

    Click image to see an enlarged view

    Fig. Install crankshaft sprocket using Sprocket Installer 6641

  2.  
  3. Install timing belt.
  4.  

Timing Belt

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009


CAUTION
The 3.5L engine is NOT a free-wheeling design. Therefore, care should be taken not to rotate the camshafts or crankshaft with the timing belt removed.

  1. Perform fuel pressure release procedure..
  2.  
  3. Disconnect negative battery cable.
  4.  
  5. Remove both cylinder head covers.
  6.  
  7. Remove the front timing belt cover.
  8.  
  9. Mark belt running direction, if timing belt is to be reused.
    CAUTION
    When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage.

  10.  
  11. Rotate engine clockwise until crankshaft mark aligns with the TDC mark on oil pump housing and the camshaft sprocket timing marks are aligned with the marks on the rear cover.
  12.  
  13. Remove the timing belt tensioner and remove timing belt.
  14.  
  15. Inspect the tensioner for fluid leakage.
  16.  
  17. Inspect the pivot and bolt for free movement, bearing grease leakage, and smooth rotation. If not rotating freely, replace the arm and pulley assembly.
  18.  
  19. When tensioner is removed from the engine it is necessary to compress the plunger into the tensioner body.
    CAUTION
    Index the tensioner in the vise the same way it is installed on the engine. This ensures proper pin orientation when tensioner is installed on the engine.

    1. Place the tensioner into a vise and SLOWLY compress the plunger. Total bleed down of tensioner should take about 5 minutes.

      Click image to see an enlarged view

      Fig. Place the tensioner into a vise and SLOWLY compress the plunger

    2.  
    3. When plunger is compressed into the tensioner body install a pin through the body and plunger to retain plunger in place until tensioner is installed.
    4.  

  20.  

To install:

Click image to see an enlarged view

Fig. Timing belt installation


CAUTION
If camshafts have moved from the timing marks, always rotate camshaft towards the direction nearest to the timing marks (DO NOT TURN CAMSHAFTS A FULL REVOLUTION OR DAMAGE to valves and/or pistons could result).

  1. Align the crankshaft sprocket (10) with the TDC mark (9) on oil pump cover.
  2.  
  3. Align the camshaft sprockets (2, 7) timing reference marks (1, 8) with the marks on the rear cover.
  4.  
  5. Install the timing belt starting at the crankshaft sprocket (10) going in a counterclockwise direction. Install the belt around the last sprocket. Maintain tension on the belt as it is positioned around the tensioner pulley (11).
    NOTE
    If the camshaft gears have been removed it is only necessary to have the camshaft gear retaining bolts installed to a snug torque at this time.

  6.  
  7. Holding the tensioner pulley (11) against the belt, install the tensioner into the housing and tighten to 21 ft. lbs. (28 Nm). Each camshaft sprocket mark should remain aligned the cover marks.
  8.  
  9. When tensioner is in place pull retaining pin to allow the tensioner to extend to the pulley bracket.
  10.  
  11. Rotate crankshaft sprocket 2 revolutions and check the timing marks on the camshafts and crankshaft. The marks should line up within their respective locations. If marks do not line up, repeat procedure.
    NOTE
    If camshaft gears have been removed and timing is correct, counterhold and tighten the camshaft gears to final torque specification.

  12.  
  13. Install the front timing belt cover.
  14.  
  15. Tighten the rocker arm assemblies and install the cylinder head covers.
  16.  
  17. Connect negative battery cable.
  18.  

 
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