Chrysler Front Wheel Drive Cars 4-CYL 1981-1995 Repair Information

Timing Belt

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REMOVAL & INSTALLATION



2.2L (Except 2.2L Turbo III) and 2.5L Except Premier Engines

See Figures 1 through 12

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Fig. Fig. 1: After raising the vehicle, remove the right inner splash shield from the vehicle



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Fig. Fig. 2: After removing the attaching bolts, pull the pulleys off of the flanges-no puller tool is necessary



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Fig. Fig. 3: Timing belt cover attaching fasteners for non-Turbo III models



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Fig. Fig. 4: Support the engine with a floor jack, then remove the engine mount through-bolt



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Fig. Fig. 5: Rotate the crankshaft until the engine is at TDC for No. 1 cylinder, then matchmark the sprockets



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Fig. Fig. 6: When at TDC, the camshaft sprocket hole should be at 12 o'clock



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Fig. Fig. 7: Loosen the timing belt idler pulley, then remove the belt



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Fig. Fig. 8: After the belt is removed, the idler pulley can also be removed



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Fig. Fig. 9: Before installing the timing belt, make sure that the engine block and sprockets' timing marks are aligned-the crankshaft and intermediate shaft timing marks should be aligned as shown



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Fig. Fig. 10: Use Special Tool C-4703 to tension the timing belt-the tool should drop to within 15 degrees of the horizontal



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Fig. Fig. 11: To double check the engine timing, position the engine at TDC for No. 1 cylinder on compression stroke, then remove the small timing hole plug-the small hole in the sprocket must be centered in the timing belt cover hole



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Fig. Fig. 12: Exploded view of the solid mount compressor bracket and related torque values

To perform this procedure, you will need a special tool No. C4703, or equivalent, to apply specified tension to the timing belt. Be careful not to allow the timing belt to come in contact with oil or any solvent, otherwise the teeth will be weakened.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the timing belt cover, as described earlier in this section.
  4.  
  5. Remove the A/C compressor with the fluid lines attached. For more information, refer to Chassis Electrical . Set the compressor aside.
  6.  
  7. Remove the alternator pivot bolt and remove the alternator.
  8.  
  9. Remove the A/C compressor belt idler unit.
  10.  
  11. Position a hydraulic floor jack under the engine. Place a long block of wood between the floor jack lifting pad and the oil pan to spread the load of the engine in such a way that the oil pan will not be damaged. Raise the engine only until its weight is taken up by the floor jack, then remove the main through-bolt from the right engine mount-the one that is situated near the timing cover.
  12.  
  13. Remove the five A/C solid mount bracket side mounting bolts (No. 1, 4, 5, 6, and 7). Remove the front mounting nut (No. 2) and remove the front bolt (No. 3). Remove the front mounting bolt and strut, rotate the solid mount bracket away from the engine and slide the bracket on stud until free. Remove the spacer from the stud.
  14.  
  15. Raise the engine slightly more for access to the crankshaft sprocket.
  16.  
  17. Using the larger bolt on the crankshaft pulley, turn the engine until the No. 1 cylinder is at TDC of the compression stroke. At this point the valves for the No. 1 cylinder will be closed and the timing mark will be aligned with the pointer on the flywheel housing. Make sure that the dots on the camshaft sprocket and cylinder head are aligned.
  18.  
  19. Loosen the tensioner pulley center nut. Then, rotate the large hex counterclockwise to reduce belt tension. Now, slide the belt off the tensioner pulley, then the crankshaft, auxiliary shaft and camshaft pulleys.
  20.  

To install:
  1. Check that the V-notch or dot on the crankshaft pulley aligns with the dot mark or line on the intermediate shaft. Check also that the arrows on the hub of the camshaft are in line with the No. 1 camshaft cap-to-cylinder head line.
  2.  

If the timing marks are not perfectly aligned, poor engine performance and probable engine damage will result!

  1. Install the belt on the pulleys with the teeth located so as to perfectly maintain the alignment off all pulleys described in the removal procedure. Install the timing belt on the camshaft sprocket first, then, while keeping the belt taut, around the intermediate shaft sprocket. Finally wrap the belt under the crankshaft sprocket. All slack in the belt should be between the camshaft and crankshaft sprocket on the tensioner side.
  2.  

If the timing marks are in line, but slack exists in the belt between either the camshaft and intermediate shaft sprockets or the intermediate and crankshaft sprockets, the timing will be incorrect when the belt is tensioned. All slack must be only between the crankshaft and camshaft sprockets.

  1. Adjust the tensioner by installing special tool C-4703, or equivalent, onto the large hex. Install the tool with the weight hanging away from the auxiliary shaft drive pulley and allow its weight to tension the belt. Position the tool so that after its tension is applied, the weight will be as close as possible to the height of the center of the pulley (the lever is horizontal). Reset the position of the tool to make sure the tool sits in this position after its tension is applied, if necessary. It must be within 15° of horizontal. Finally, tighten the tensioner locknut to 32 ft. lbs. (44 Nm) for 1981-88 models, or to 45 ft. lbs. (61 Nm) for 1989-95 models. Do not tighten the tensioner tool too tight, otherwise it could cause the belt to howl or possibly break.
  2.  
  3. Rotate the engine 2 full revolutions by the center crankshaft pulley bolt and recheck that the timing marks on the camshaft, crankshaft and intermediate sprockets are correctly aligned as during the removal procedure. If necessary, alter the position of the belt teeth to correct timing and reset the tension.
  4.  
  5. For vehicles with A/C and solid mount compressors, install the solid mount compressor bracket as follows:
    1. Position the spacer onto the stud, then install the bracket on the front (2 nut) mounting stud and slide the bracket over the timing belt cover into position.
    2.  
    3. Loosen the assembly bracket-to-engine fasteners (numbered 1 through 7-refer to the accompanying illustration).
    4.  

  6.  


WARNING
The bracket fasteners must be tightened in the proper sequence and to the specified torque values.

  1. Tighten the fasteners in the following sequence: 1) bolt 1 to 30 inch lbs. (3.3 Nm), 2) nut 2 and bolt 3 to 40 ft. lbs. (54 Nm), 3) bolts 1, 4 and 5 to 40 ft. lbs. (54 Nm), 4) bolts 6 and 7 to 40 ft. lbs. (54 Nm).
  2.  
  3. Install the alternator and compressor to the bracket. Tighten the compressor mounting bolts to 40 ft. lbs. (54 Nm).
  4.  

  1. Install the timing belt cover and pulleys.
  2.  
  3. Lower the engine and reassemble the engine mount, tightening the through-bolt to 70 ft. lbs. (95 Nm).
  4.  
  5. Remove the floor jack from under the engine.
  6.  
  7. Install the timing belt covers, as described earlier in this section.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Adjust the ignition timing, if necessary.
  12.  

2.2L Turbo III Engine

See Figures 1 and 2, and 13 through 20

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Fig. Fig. 13: Upper and lower timing belt cover fasteners for 2.2L Turbo III models



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Fig. Fig. 14: Timing belt and some related components for the 2.2L Turbo III engine



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Fig. Fig. 15: Loosen the rocker arm shaft hold-down = fasteners in the sequence shown approximately 3 revolutions



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Fig. Fig. 16: Align and pin both intake and exhaust camshaft sprockets with 3/32 in. drill bits or pin punches, as shown



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Fig. Fig. 17: Use a dial indicator to help locate Top Dead Center (TDC), then matchmark the crankshaft sprocket to the engine block for reference



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Fig. Fig. 18: Install the timing belt onto the sprockets in a counterclockwise direction starting with the crankshaft sprocket



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Fig. Fig. 19: Install a belt tension gauge in the position shown, then tighten tension the timing belt to 110 lbs. (445 N) for a new belt, or to 70 lbs. (311 N) for a used belt



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Fig. Fig. 20: Tighten the rocker arm shaft hold-down bolts in the sequence shown first to 105 inch lbs. (12 Nm), then to 18 ft. lbs. (24 Nm)

  1. Disconnect the negative battery cable.
  2.  
  3. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  4.  
  5. Remove the timing belt covers, as described previously in this section.
  6.  
  7. Remove the A/C compressor with the fluid lines attached. For more information, refer to Chassis Electrical . Set the compressor aside.
  8.  
  9. Remove the alternator pivot bolt and remove the alternator.
  10.  
  11. Remove the A/C compressor belt idler unit.
  12.  
  13. Position a hydraulic floor jack under the engine. Place a long block of wood between the floor jack lifting pad and the oil pan to spread the load of the engine in such a way that the oil pan will not be damaged. Raise the engine only until its weight is taken up by the floor jack, then remove the main through-bolt from the right engine mount-the one that is situated near the timing cover.
  14.  
  15. Remove the five A/C solid mount bracket side mounting bolts (No. 1, 4, 5, 6, and 7). Remove the front mounting nut (No. 2) and remove the front bolt (No. 3). Remove the front mounting bolt and strut, rotate the solid mount bracket away from the engine and slide the bracket on stud until free. Remove the spacer from the stud.
  16.  
  17. Remove the lower accessory drive belt idler pulley bracket assembly.
  18.  
  19. Loosen the timing belt tensioner, then remove the timing belt and idler pulley.
  20.  

To install:
  1. Remove the air cleaner fresh air duct, ignition cable cover, spark plugs and rocker arm covers, as described earlier in this section and in Routine Maintenance .
  2.  
  3. Loosen the rocker arm retaining bolts about 3 turns in the proper sequence. Check all lash adjusters and replace any that are damaged.
  4.  
  5. Align and pin both camshaft sprockets with 3 / 16 in. drill bits or pin punches to hold them steady while installing the timing belt.
  6.  
  7. Install a dial indicator so that the plunger extends down into the No. 1 spark plug hole. Rotate the crankshaft until the No. 1 piston is at TDC (the dial indicator will register the highest position of the crankshaft). Matchmark the crankshaft and camshaft sprockets to the engine block for reference.
  8.  

Since there is no distributor, the intermediate shaft sprocket does not need to be timed.

  1. Install the timing belt and idler pulley starting at the crankshaft and working counterclockwise. Make sure there is no slack between any sprockets, except for the camshaft and crankshaft pulleys on the idler pulley side, when installing. All timing belt slack should be on the idler pulley side of the engine.
  2.  
  3. Install a suitable belt tension gauge on the timing belt between the camshaft sprockets. Remove the pins from the camshaft sprockets.
  4.  


WARNING
The belt tension gauge must be installed between the belt teeth to get an accurate reading.

  1. Rotate the tensioner clockwise to adjust the belt tension to 110 lbs. (445 N). for a new belt, or to 70 lbs. (311 N) for an old belt. Tighten the tensioner bolt 39 ft. lbs. (53 Nm).
  2.  
  3. Rotate the crankshaft clockwise 2 revolutions and recheck that the timing marks on the camshaft and crankshaft sprockets align with the timing marks on the engine. Also double-check belt tension, adjust as required.
  4.  
  5. Remove the dial indicator from the cylinder head valley.
  6.  
  7. Tighten the rocker arm bolts in sequence to 18 ft. lbs. (24 Nm).
  8.  
  9. For vehicles with A/C and solid mount compressors, install the solid mount compressor bracket as follows:
    1. Position the spacer onto the stud, then install the bracket on the front (2 nut) mounting stud and slide the bracket over the timing belt cover into position.
    2.  
    3. Loosen the assembly bracket-to-engine fasteners (numbered 1 through 7-refer to the accompanying illustration).
    4.  

  10.  


WARNING
The bracket fasteners must be tightened in the proper sequence and to the specified torque values.

  1. Tighten the fasteners in the following sequence: 1) bolt 1 to 30 inch lbs. (3.3 Nm), 2) nut 2 and bolt 3 to 40 ft. lbs. (54 Nm), 3) bolts 1, 4 and 5 to 40 ft. lbs. (54 Nm), 4) bolts 6 and 7 to 40 ft. lbs. (54 Nm).
  2.  
  3. Install the alternator and compressor to the bracket. Tighten the compressor mounting bolts to 40 ft. lbs. (54 Nm).
  4.  

  1. Install engine mount and timing belt covers.
  2.  
  3. Install the spark plugs, rocker arm covers, ignition cable cover and air duct.
  4.  
  5. Connect the negative battery cable, start the engine and check for leaks.
  6.  

ADJUSTMENT



Use these procedure to adjust the timing belt if it was not removed from the engine.

2.2L (Except 2.2L Turbo III) and 2.5L Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  4.  
  5. Remove the right front inner splash shield.
  6.  
  7. Remove the timing belt tensioner cover.
  8.  
  9. Position Special Tensioning Tool C-4703, or equivalent, on the hex of the tensioner so that its weight is approximately at the 10 o'clock position, then loosen the bolt.
  10.  
  11. The tensioner should drop to the 9 o'clock position. Reposition the tool as required in order to have it end up at the 9 o'clock position (parallel to the ground, hanging toward the rear of the vehicle) with a range to approximately 15° above and below the 9 o'clock position.
  12.  
  13. Hold the tensioning tool in position and tighten the bolt. Do not pull the tool past the 9 o'clock position or the belt will be too tight and will cause howling or possible breakage. Tighten the tensioner locknut to 32 ft. lbs. (44 Nm) for 1981-88 models, or to 45 ft. lbs. (61 Nm) for 1989-95 models.
  14.  
  15. Install the tensioner cover and the splash shield.
  16.  
  17. Lower the vehicle and remove the wheel blocks.
  18.  
  19. Connect the negative battery cable.
  20.  

2.2L Turbo III Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the timing covers.
  4.  
  5. Install a suitable belt tension gauge on the timing belt between the camshaft sprockets.
  6.  
  7. Rotate the tensioner clockwise to adjust the belt tension to 70 lbs. (311 N). This tensioning value is for a used timing belt.
  8.  
  9. Rotate the crankshaft clockwise 2 revolutions and recheck the tension. Readjust as required.
  10.  
  11. Install the timing covers.
  12.  
  13. Connect the negative battery cable.
  14.  

 
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