Avenger, Sebring Coupe, Stratus Coupe, 1999-2006

Timing Belt & Sprockets

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Removal & Installation



2.4L (VIN X) 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 engine mount bracket.
  14.  
  15. Remove the timing belt cover.
    NOTE
    Do not rotate the crankshaft or the camshafts after the timing belt has been removed. Damage to the valve components may occur. Before removing the timing belt, always align the timing marks.

  16.  
  17. Align the timing marks of the timing belt sprockets to the timing marks on the rear timing belt cover and oil pump cover. Loosen the timing belt tensioner bolts.
  18.  
  19. Remove the timing belt and the tensioner.
  20.  
  21. Remove the camshaft timing belt sprockets.
  22.  
  23. Remove the crankshaft timing belt sprocket using special removal tool No. 6793.
  24.  
  25. Place the tensioner into a soft-jawed vise to compress the tensioner.
  26.  
  27. After compressing the tensioner, place a pin (a 5 / 64 inch Allen wrench will work) into the plunger side hole to retain the plunger until installation.

    Click image to see an enlarged view

    Fig. Timing belt cover bolt locations-2.4L (VIN X) Engine



    Click image to see an enlarged view

    Fig. Crankshaft and camshaft alignment marks-2.4L (VIN X) Engine

  28.  

To install:

  1. Using special tool No. 6792, install the crankshaft timing belt sprocket onto the crankshaft.
  2.  
  3. Install the camshaft sprockets onto the camshafts. Install and tighten the camshaft sprocket bolts to 75 ft. lbs. (101 Nm).
  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.
  6.  
  7. Set the camshafts to align the timing marks on the sprockets.
  8.  
  9. Move the crankshaft to 1 / 2 notch before TDC.
  10.  
  11. Install the timing belt starting at the crankshaft, then around the water pump sprocket, idler pulley, camshaft sprockets and the tensioner pulley.
  12.  
  13. Move the crankshaft sprocket to TDC to take up the belt slack.
  14.  
  15. Reinstall the tensioner to the block but do not tighten it at this time.
  16.  
  17. Using a torque wrench on the tensioner pulley, apply 21 ft. lbs. (28 Nm) of torque to the tensioner pulley.
  18.  
  19. With torque being applied to the tensioner pulley, move the tensioner up against the tensioner pulley bracket and tighten the fasteners to 23 ft. lbs. (31 Nm).
  20.  
  21. Remove the tensioner plunger pin, the tension is correct when the plunger pin can be removed and replaced easily.
  22.  
  23. Rotate the crankshaft two revolutions and recheck the timing marks. Wait several minutes, then recheck that the plunger pin can easily be removed and installed.
  24.  
  25. Reinstall the front timing belt cover.
  26.  
  27. Reinstall the engine mount bracket.
  28.  
  29. Reinstall the right engine mount.
  30.  
  31. Remove the floor jack from under the vehicle.
  32.  
  33. Install the crankshaft damper and tighten to 105 ft. lbs. (142 Nm).
  34.  
  35. Install and adjust the accessory drive belts.
  36.  
  37. Install the right inner splash-shield.
  38.  
  39. Reconnect the negative battery cable.
  40.  
  41. Perform the crankshaft and camshaft relearn alignment procedure using the DRB scan tool or equivalent.
  42.  

2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. 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.
  4.  
  5. Remove the right inner splash-shield.
  6.  
  7. Remove the accessory drive belts.
  8.  
  9. Remove the Crankshaft damper.
  10.  
  11. Remove the right engine mount.
  12.  
  13. Place a suitable floor jack under the vehicle to support the engine.
  14.  
  15. Remove the engine mount bracket.
  16.  
  17. Remove the timing belt cover.
    WARNING
    Do not rotate the crankshaft or the camshafts after the timing belt has been removed. Damage to the valve components may occur. Before removing the timing belt, always align the timing marks.

  18.  
  19. Align the timing marks of the timing belt sprockets to the timing marks on the rear timing belt cover and oil pump cover. Loosen the timing belt tensioner bolts.
  20.  
  21. Remove the timing belt and the tensioner.
  22.  
  23. Remove the camshaft timing belt sprockets.
  24.  
  25. Remove the crankshaft timing belt sprocket using special removal tool No. 6793.
  26.  
  27. Place the tensioner into a soft-jawed vise to compress the tensioner.
  28.  
  29. After compressing the tensioner, place a pin (a 5 / 64 inch Allen wrench will work) into the plunger side hole to retain the plunger until installation.

    Click image to see an enlarged view

    Fig. Timing belt cover bolt locations-2.4L engine



    Click image to see an enlarged view

    Fig. Crankshaft and camshaft alignment marks-2.4L engine

  30.  

To install:

  1. Using special tool No. 6792, install the crankshaft timing belt sprocket onto the crankshaft.
  2.  
  3. Install the camshaft sprockets onto the camshafts. Install and tighten the camshaft sprocket bolts to 75 ft. lbs. (101 Nm).
  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.
  6.  
  7. Set the camshafts to align the timing marks on the sprockets.
  8.  
  9. Move the crankshaft to 1 / 2 notch before TDC.
  10.  
  11. Install the timing belt starting at the crankshaft, then around the water pump sprocket, idler pulley, camshaft sprockets and the tensioner pulley.
  12.  
  13. Move the crankshaft sprocket to TDC to take up the belt slack.
  14.  
  15. Reinstall the tensioner to the block, but do not tighten it at this time.
  16.  
  17. Using a torque wrench on the tensioner pulley, apply 21 ft. lbs. (28 Nm) of torque to the tensioner pulley.
  18.  
  19. With torque being applied to the tensioner pulley, move the tensioner up against the tensioner pulley bracket and tighten the fasteners to 23 ft. lbs. (31 Nm).
  20.  
  21. Remove the tensioner plunger pin, the tension is correct when the plunger pin can be removed and replaced easily.
  22.  
  23. Rotate the crankshaft 2 revolutions and recheck the timing marks. Wait several minutes, then recheck that the plunger pin can easily be removed and installed.
  24.  
  25. Install the front timing belt cover.
  26.  
  27. Install the engine mount bracket.
  28.  
  29. Install the right engine mount.
  30.  
  31. Remove the floor jack from under the vehicle.
  32.  
  33. Install the Crankshaft damper and tighten to 105 ft. lbs. (142 Nm).
  34.  
  35. Install and adjust the accessory drive belts.
  36.  
  37. Install the right inner splash-shield.
  38.  
  39. Reconnect the negative battery cable.
  40.  
  41. Perform the crankshaft and camshaft relearn alignment procedure using the DRBIII® scan tool or equivalent.
  42.  

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 the a binder clip on the belt to the sprocket so it won't slip out of position.
  12.  
  13. Keeping the belt taut, install the it under the water pump pulley and around the front camshaft sprocket.
  14.  
  15. Install the 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 the 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 a scan tool.
  48.  

 
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