Breeze, Cirrus, Sebring Convertible and Sedan, Stratus Sedan, 1999-2005

Timing Belt & Tensioner

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Removal & Installation



2.0L (VIN C) SOHC 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 drive belts and accessories.
  4.  
  5. Remove the right inner splash-shield.
  6.  
  7. Remove the crankshaft damper.
  8.  
  9. Remove the right engine mount.
  10.  
  11. Place a support under the engine.
  12.  
  13. Remove the engine mount bracket.
  14.  
  15. Remove the timing belt cover.
  16.  
  17. Loosen the timing belt tensioner bolts.
  18.  
  19. Remove the timing belt and the tensioner.
    NOTE
    When the tensioner is removed from the engine it is necessary to compress the plunger into the tensioner body.

  20.  
  21. Place the tensioner in a soft-jawed vise to compress the tensioner.
  22.  
  23. 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. TDC alignment for timing belt installation-2.0L (VIN C) SOHC Engine

  24.  

To install:

  1. 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.
  2.  
  3. Set the camshaft to align the timing marks.
  4.  
  5. Move the crankshaft to 1 / 2 notch before TDC.
  6.  
  7. Install the timing belt starting at the crankshaft, around the water pump, then around the camshaft last.
  8.  
  9. Move the crankshaft to TDC to take up the belt slack.
  10.  
  11. Reinstall the tensioner to the block but do not tighten it.
  12.  
  13. Using a torque wrench apply 21 ft. lbs. (28 Nm) of torque to the tensioner pulley.
  14.  
  15. With torque being applied to the tensioner pulley, move the tensioner up against the tensioner bracket and tighten the fasteners to 23 ft. lbs. (31 Nm).
  16.  
  17. Remove the tensioner plunger pin, the tension is correct when the plunger pin can be removed and replaced easily.
  18.  
  19. Rotate the crankshaft two revolutions and recheck the timing marks.
  20.  
  21. Reinstall the timing belt cover.
  22.  
  23. Reinstall the engine mount bracket.
  24.  
  25. Reinstall the right engine mount.
  26.  
  27. Remove the engine support.
  28.  
  29. Reinstall the crankshaft damper and tighten to 105 ft. lbs. (142 Nm).
  30.  
  31. Reinstall the drive belts and accessories.
  32.  
  33. Reinstall the right inner splash-shield.
  34.  
  35. Perform the crankshaft and camshaft relearn alignment procedure using the scan tool.
  36.  

2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
  4.  
  5. Place a suitable floor jack under the vehicle to support the engine.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Engine mount insulator mounting bolt
     
    Engine mount bracket
     
    Engine mount stopper
     

  8.  
  9. Remove or disconnect the following:

    Right inner splash-shield
     
    Radiator reservoir tank
     
    Accessory drive belts
     
    Water pump pulley
     
    Crankshaft damper/pulley
     
    Timing belt upper and lower covers
     

  10.  
  11. Align the timing marks of the timing belt sprockets to the timing marks on the rear timing belt cover and oil pump 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.

  12.  
  13. Remove or disconnect the following:
    NOTE
    If the timing belt is to be reused, draw an arrow indicating the direction of rotation on the back of the belt for reinstallation.



    Timing belt
     
    Tensioner pulley
     
    Auto-tensioner
     

  14.  
  15. Loosen the timing belt tension pulley fixing bolt, then move the tension pulley to the water pump side.
    NOTE
    Snugging the bolt when the tension pulley is on the water pump side will facilitate removal of the timing belt.



    Click image to see an enlarged view

    Fig. Engine bracket removal-2.4L engine



    Click image to see an enlarged view

    Fig. Turn the crankshaft in the forward direction only to align the timing marks-2.4L engine



    Click image to see an enlarged view

    Fig. Location of the tension pulley fixing bolt-2.4L engine



    Click image to see an enlarged view

    Fig. Exploded view of the timing belt and related components-2.4L engine

  16.  

To install:

  1. Apply 22-44 lbs. (98-196 N) of force to the pushrod of the auto tensioner by pushing it against a metal object (ex. engine block). Measure the movement of the pushrod. Standard value is within 0.04 in. (1mm). A is the length when it is free (not pressed). B is the length when it is pressed. If the measurement is outside A minus B, replace the tensioner.
  2.  
  3. Place the tensioner in a vise and slowly compress the pushrod until pin hole A of the pushrod and pinhole B of the tensioner cylinder are aligned. Press slowly to avoid damaging the pushrod. When the holes are aligned, insert a suitable pin to lock the pushrod in the compressed position.
    NOTE
    When replacing the tensioner with a new part, it will come pre-compressed with a pin.

  4.  
  5. Align the timing marks on the camshaft sprocket, crankshaft sprocket and oil pump sprocket.
  6.  
  7. Remove the cylinder block plug and insert a Phillips head 0.3 inch (8mm) screwdriver. The screwdriver must go in 2.4 inches (60mm) or more. If the screwdriver only goes in 0.8-1.0 inch (20-25mm), it is hitting the counterbalance shaft. If the screwdriver hits the counterbalance shaft, turn the sprocket once, realign the marks and insert the screwdriver again. Do not take the screwdriver out until the timing belt is installed.
  8.  
  9. Install or connect the following:

    Timing belt starting at the crankshaft, oil pump sprocket and camshaft sprocket, in that order, so there is no slack.
     

  10.  
  11. Set the tension pulley so that the pin holes are at the bottom, press the tension pulley lightly against the timing belt and tighten the fixing bolt.
  12.  
  13. Adjust belt tension as follows:
    1. After turning the crankshaft 1 / 4 revolution counterclockwise, turn it in the clockwise direction until the timing marks are aligned.
      WARNING
      When tightening the fixing bolt, make sure the tension pulley does not turn with the bolt.

    2.  
    3. Loosen the tension pulley fixing bolt, and use special tool MD998767 or a suitable timing belt tensioning tool and tighten the fixing bolt to 32-40 ft. lbs. (42-54 Nm) while applying tension of 31 inch lbs. (3.5 Nm) to the timing belt.
      NOTE
      You will need a beam-type or torque wrench or a torque-measuring wrench



      Click image to see an enlarged view

      Fig. Measuring the auto tensioner-2.4L engine



      Click image to see an enlarged view

      Fig. Compress the pushrod until holes A & B are aligned-2.4L engine



      Click image to see an enlarged view

      Fig. Tensioning timing belt with Special Tool MD998767

    4.  
    5. Remove the set pin from the tensioner.
    6.  
    7. Turn the crankshaft 2 revolutions clockwise so that the timing marks are aligned. After leaving it for 15 minutes, measure the amount of protrusion of the auto-tensioner. It should be 0.15-0.18 in. (3.8-5.5 Nm). If the measurement is outside the specifications, repeat steps A.-D.
    8.  
    9. Make sure the timing marks of each sprocket are still aligned.

      Front and rear timing belt covers
       
      Engine mount stopper
       
      Engine mount bracket
       
      Engine mount insulator mounting bolt and tighten to 60 ft. lbs. (81 Nm)
       

    10.  

  14.  
  15. Remove the floor jack from under the vehicle.

    Crankshaft damper and tighten the bolts to 18 ft. lbs. (25 Nm)
     
    Water pump pulley
     
    Accessory drive belts
     
    Radiator reservoir tank
     
    Right inner splash-shield
     

  16.  
  17. Properly fill the cooling system.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Check for leaks and proper engine and cooling system operation.
  22.  

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 hoses 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 valve train 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 the 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) engine

  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 inch (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 tensioning procedure.
  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.  

2.5L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
  4.  
  5. Remove the accessory drive belts.
  6.  
  7. Using Crankshaft Holding Tools MB990767 and MB998754, remove the crankshaft bolt and remove the pulley.
  8.  
  9. Remove the heated oxygen sensor connection.
  10.  
  11. Remove the power steering pump with the hose attached and position it aside.
  12.  
  13. Remove the power steering pump bracket.
  14.  
  15. 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.
  16.  
  17. 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.

  18.  
  19. Remove the front timing belt covers.
  20.  
  21. If the timing belt is to be reused, draw an arrow indicating the direction of rotation on the back of the belt for reinstallation.
  22.  
  23. 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.

  24.  
  25. Check the belt tensioner for leaks and check the pushrod for cracks.
  26.  
  27. 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.
  28.  
  29. 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.

  30.  
  31. 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-2.5L engines

  32.  

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.  

3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
  4.  
  5. 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.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Sometimes the bolt can be seized due to corrosion. Spraying lubricant, slowly remove the alignment bolt and remaining bolts and remove the engine support bracket.


    NOTE
    If the timing belt is to be reused, draw an arrow indicating the direction of rotation on the back of the belt for reinstallation.



    Upper engine mount.
     



    Negative battery cable
     
    Alternator
     
    Accessory drive belts
     
    Crankshaft bolt and pulley, using Crankshaft Holding Tools MB990767 and MB998754/MD998715
     
    Heated oxygen sensor connection, if necessary
     
    Power steering pump (leaving the hose attached) and position it aside
     
    Power steering pump bracket
     
    Tensioner pulley assembly
     
    Upper right front timing belt cover
     
    Upper left front timing belt cover
     

  8.  
  9. 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.

  10.  
  11. 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.
  12.  
  13. Place the tensioner in a vise and slowly compress the plunger. Take care not to damage the pushrod. If there is a plug at the end of the tensioner, place a plain washer over the plug to protect it from damage while compressing.
    NOTE
    Position the tensioner perpendicular to the vise jaws, taking care to insert the pin so it can still be removed after the tensioner is installed on the engine.

  14.  
  15. 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. Exploded view of the timing belt and related components-3.0L engine



    Click image to see an enlarged view

    Fig. Alignment of the timing marks-3.0L engine



    Click image to see an enlarged view

    Fig. Orientation of plain washer to protect plug from damage-3.0L engine

  16.  

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 push the tensioner pulley into the timing belt so that it 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.
  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 the installation steps.
  18.  
  19. Install or connect the following:

    Timing belt covers
     
    Engine mounting bracket
     

  20.  
  21. Lower the engine enough to install the engine mount onto bracket and remove the floor jack.

    Power steering pump bracket and pump
     
    Crankshaft pulley and tighten the retaining bolt to 137 ft. lbs. (185 Nm)
     
    Accessory drive belts
     

  22.  
  23. Properly fill the cooling system.
  24.  
  25. Connect the negative battery cable.
  26.  
  27. Check for leaks and proper engine and cooling system operation.
  28.  

 
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