Chrysler Neon 1995-1999 Repair Guide

Timing Belt and Sprockets

Print

INSPECTION



See Figures 1 through 8


WARNING
Timing belt maintenance is extremely important! All Neon models utilize an interference-type, non-free-wheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. The recommended replacement interval for the timing belt is 102,000 miles (163,000km), or sooner.

You would be wise to check the belt periodically to make sure it has not become damaged or worn. Generally speaking, a severely worn belt may cause engine performance to drop dramatically, but a damaged belt (which could give out suddenly) may not give as much warning. In general, any time the engine timing cover(s) is(are) removed you should inspect the belt for premature parting, severe cracks or missing teeth. Also, an access plug or cover is provided in the upper portion of the timing cover so that camshaft timing can be checked without cover removal. If timing is found to be off, cover removal and further belt inspection or replacement is necessary.



Click image to see an enlarged view

Fig. Fig. 1: Check for premature parting of the belt



Click image to see an enlarged view

Fig. Fig. 2: Check if the teeth are cracked or damaged



Click image to see an enlarged view

Fig. Fig. 3: Look for noticeable cracks or wear on the belt face



Click image to see an enlarged view

Fig. Fig. 4: You may only have damage on one side of the belt; if so, the guide could be the culprit



Click image to see an enlarged view

Fig. Fig. 5: Foreign materials can get in between the teeth and cause damage



Click image to see an enlarged view

Fig. Fig. 6: Inspect the timing belt for cracks, fraying, glazing or damage of any kind



Click image to see an enlarged view

Fig. Fig. 7: Damage on only one side of the timing belt may indicate a faulty guide



Click image to see an enlarged view

Fig. Fig. 8: ALWAYS replace the timing belt at the interval specified by the manufacturer

REMOVAL & INSTALLATION




WARNING
NEVER rotate the camshaft(s) or crankshaft after the timing belt is removed! This could damage the valve train components. Always align the timing marks before removing the timing belt.

With Hydraulic Tensioner

See Figures 9 through 23

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the timing belt cover, as outlined earlier in this section.
  4.  



Click image to see an enlarged view

Fig. Fig. 9: Remove the timing belt cover

  1. Align the camshaft timing marks.
  2.  



Click image to see an enlarged view

Fig. Fig. 10: Make sure the camshaft sprocket timing mark (1) aligns with the arrow (2) on the rear belt cover ...



Click image to see an enlarged view

Fig. Fig. 11: ... and the crankshaft sprocket timing mark (1) is aligned with the arrow (2)

  1. Loosen the hydraulic timing belt tensioner retainers, then remove the timing belt. Do NOT loosen, tighten or remove the tensioner pivot bolt.
  2.  



Click image to see an enlarged view

Fig. Fig. 12: Do NOT loosen, tighten or remove the tensioner pivot bolt



Click image to see an enlarged view

Fig. Fig. 13: Remove the 2 timing belt tensioner retaining bolts ...



Click image to see an enlarged view

Fig. Fig. 14: ... then remove the timing belt from the sprockets

  1. If necessary, use a special tool or spanner wrench to hold the camshaft sprocket stationary, then unfasten the bolt and remove the sprocket.
  2.  



Click image to see an enlarged view

Fig. Fig. 15: If necessary, use the special tool or a spanner wrench to hold the cam sprocket, then unfasten the bolt and remove the sprocket



Click image to see an enlarged view

Fig. Fig. 16: Exploded view of the timing belt and related components-DOHC with hydraulic tensioner shown, SOHC similar

To install:
  1. When the tensioner is removed from the engine, you must compression the plunger back into the tensioner body for installation, as follows:
    1. Place the hydraulic tensioner in a vise, then slowly compress the plunger.

      Click image to see an enlarged view

      Fig. Fig. 17: Install the timing belt tensioner in a vise

    2.  

  2.  

Index the tensioner in the vise the same way it is installed on the engine. This will ensure proper pin orientation when the tensioner is installed on the engine.

  1. When the plunger is compressed into the tensioner body, install a 5 / 64 in. (9mm) hex pin through the body and plunger. This will keep the plunger in place until the tensioner is installed.
  2.  



Click image to see an enlarged view

Fig. Fig. 18: Use the vise to slowly compress the tensioner plunger so the holes in the plunger and the body align ...



Click image to see an enlarged view

Fig. Fig. 19: ... then insert a 5/64 in. (1.9mm) Allen wrench through the holes to hold the plunger in place

  1. If removed, install the camshaft sprocket(s) and secure with the retaining bolts.
  2.  
  3. Set the crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing, then back off 3 notches before TDC.
  4.  



Click image to see an enlarged view

Fig. Fig. 20: Align the crankshaft sprocket with the arrow on the oil pump housing, then back off 3 notches for TDC

  1. Set the camshaft timing marks together by aligning the notches on the sprockets.
  2.  



Click image to see an enlarged view

Fig. Fig. 21: Align the notches on the camshaft sprockets

  1. Rotate the crankshaft 1 / 2 tooth counterclockwise from TDC.
  2.  



Click image to see an enlarged view

Fig. Fig. 22: Rotate the crankshaft 1/2 tooth counterclockwise from Top Dead Center (TDC)

  1. Install the timing belt in this direction. Starting at the crankshaft, go around the water pump sprocket, idler pulley, camshaft sprockets and then around the tensioner pulley.
  2.  
  3. Move the crankshaft sprocket to TDC to take up the belt slack. Install the tensioner to the block but do not tighten the fasteners yet.
  4.  
  5. Using a torque wrench on the tensioner pulley, apply 21 ft. lbs. (28 Nm). or torque to the tensioner.
  6.  



Click image to see an enlarged view

Fig. Fig. 23: Adjusting the timing belt tension

  1. 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).
  2.  
  3. Pull the tensioner plunger pin. The pretension is correct when the pin can be removed and installed freely.
  4.  
  5. Rotate the crankshaft 2 revolutions and check the alignment of the timing marks.
  6.  
  7. Install the front timing belt cover, as outlined earlier in this section.
  8.  

With Mechanical Tensioner

See Figures 24, 25, 26 and 27

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the timing belt cover, as outlined earlier in this section.
  4.  


WARNING
Align the camshaft and crankshaft timing marks before removing the timing belt by rotating the engine with the crankshaft. NEVER rotate the camshaft once the timing belt has been removed because damage to the valve components may occur.

  1. Align the camshaft timing mark(s) and crankshaft timing mark with the arrow on the oil pump housing.
  2.  
  3. Insert an 8mm Allen wrench into the timing belt tensioner. Insert the long end of the 1 / 8 in. (3mm) Allen wrench into the pin hole on the front of the tensioner.
  4.  
  5. Rotate the tensioner counterclockwise with the Allen wrench, while pushing in lightly with the 1 / 8 in. (3mm) Allen wrench, until it slides into the locking hole.
  6.  



Click image to see an enlarged view

Fig. Fig. 24: Insert the 2 Allen wrenches into the tensioner to free the timing belt

  1. Remove the timing belt from the engine.
  2.  
  3. If necessary, remove the tensioner by unfastening the attaching bolts. The timing belt tensioner is serviced as an assembly. To prevent premature timing belt failure and engine damage, DO NOT separate the tensioner pulley from the mounting bracket.
  4.  



Click image to see an enlarged view

Fig. Fig. 25: Location of the mechanical tensioner retaining bolts



Click image to see an enlarged view

Fig. Fig. 26: Exploded view of the timing belt and related components-DOHC with mechanical tensioner shown, SOHC similar

  1. If necessary, use a special tool or spanner wrench to hold the camshaft sprocket stationary, then unfasten the bolt and remove the sprocket.
  2.  

To install:
  1. If removed, install the camshaft sprocket(s) and secure with the retaining bolts.
  2.  
  3. If removed, install the timing belt tensioner. Install the retaining bolts and tighten to 21 ft. lbs. (28 Nm).
  4.  
  5. Set the crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing, then back off 3 notches before TDC.
  6.  
  7. Set the camshaft timing marks together by aligning the notches on the sprockets.
  8.  
  9. Rotate the crankshaft 1 / 2 tooth counterclockwise from TDC.
  10.  
  11. Install the timing belt in this direction. Starting at the crankshaft, go around the water pump sprocket, idler pulley, camshaft sprocket(s) and then around the tensioner pulley.
  12.  
  13. Move the crankshaft sprocket to TDC to take up the belt slack.
  14.  



Click image to see an enlarged view

Fig. Fig. 27: Move the crankshaft sprocket to TDC to take up the belt slack

  1. Release the tensioner by removing the pin or Allen wrench from the belt tensioner.
  2.  
  3. Rotate the crankshaft 2 revolutions and check the alignment of the timing marks.
  4.  
  5. Install the timing belt cover, as outlined earlier in this section.
  6.  
  7. Connect the negative battery cable.
  8.  

 
label.common.footer.alt.autozoneLogo