Neon, 2000 - 2005

Timing Belt and Sprockets 2.0L (VIN F) Engine

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2.0L (VIN F) Engine



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine undercover
     
    Engine mount bracket
     
    Drive belts
     
    Belt tensioner pulley
     
    Water pump pulleys
     
    Crankshaft pulley.
     
    Stud bolt from the engine support bracket, then remove the timing belt covers
     

  4.  
  5. Rotate the crankshaft clockwise to align the camshaft timing marks. Always turn the crankshaft in the forward direction only.
  6.  
  7. Loosen the tension pulley center bolt.
    NOTE
    If the timing belt is to be reused, mark the direction of rotation on the flat side of the belt with an arrow.

  8.  
  9. Move the tension pulley towards the water pump and remove the timing belt.
  10.  
  11. Remove the crankshaft sprocket center bolt using special tool MB990767 to hold the crankshaft sprocket while removing the center bolt. Then, use MB998778 puller to remove the sprocket.
  12.  
  13. Mark the direction of rotation on the timing belt -B- with a arrow.
  14.  
  15. Loosen the center bolt on the tensioner and remove the belt.
  16.  
  17. To remove the camshaft sprocket, remove the cylinder head cover. Use a wrench to hold the hexagonal part of the camshaft and remove the sprocket mounting bolt.
    WARNING
    Do not rotate the camshafts or the crankshaft while the timing belt is removed.



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    Fig. Notice the timing mark on the oil pump drive sprocket-2.0L (VIN F) engines



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    Fig. Timing belt -B- timing marks locations-2.0L (VIN F) engines

  18.  

To install:

  1. Use a wrench to hold the camshaft, then install the sprocket and mounting bolt. Tighten the bolt(s) to 65 ft. lbs. (88 Nm).
  2.  
  3. Install the cylinder head cover.
  4.  
  5. Place the crankshaft sprocket on the crankshaft. Use tool MB990767 to hold the crankshaft sprocket while tightening the center bolt. Tighten the center bolt to 80-94 ft. lbs. (108-127 Nm).
  6.  
  7. Align the timing marks on the crankshaft sprocket -B- and the balance shaft.
  8.  
  9. Install timing belt -B- on the sprockets. Position the center of the tensioner pulley to the left and above the center of the mounting bolt.
  10.  
  11. Push the pulley clockwise toward the crankshaft to apply tension to the belt and tighten the mounting bolt to 14 ft. lbs. (19 Nm). Do not let the pulley turn when tightening the bolt because it will cause excessive tension on the belt. The belt should deflect 0.20-0.28 inch (5-7mm) when finger pressure is applied between the pulleys.
  12.  
  13. Install the crankshaft sensing blade and the crankshaft sprocket. Apply engine oil to the mounting bolt and tighten the bolt to 80-94 ft. lbs. (108-127 Nm).
  14.  
  15. Use a press or vise to compress the auto tensioner pushrod. Insert a set pin when the holes are aligned.
    WARNING
    Do not compress the pushrod too quickly, damage to the pushrod can occur.

  16.  
  17. Install the auto tensioner on the engine.
  18.  
  19. Align the timing marks on the camshaft sprocket, crankshaft sprocket and the oil pump sprocket.
  20.  
  21. After aligning the mark on the oil pump sprocket, remove the cylinder block plug and insert a Phillips screwdriver in the hole to check the position of the counter balance shaft. The screwdriver should go in at least 2.36 inch or more. If not, rotate the oil pump sprocket once and realign the timing mark so the screwdriver goes in. Do not remove the screwdriver until the timing belt is installed.
  22.  
  23. Install or connect the following:

    Timing belt on the intake camshaft and secure it with a clip
     
    Timing belt on the exhaust camshaft. Align the timing marks with the cylinder head top surface using two wrenches. Secure the belt with another clip.
     
    Belt around the idler pulley, oil pump sprocket, crankshaft sprocket and the tensioner pulley
     

  24.  
  25. Turn the tension pulley so the pinholes are at the bottom. Press the pulley lightly against the timing belt.
  26.  
  27. Screw the special tool into the left engine support bracket until it contacts the tensioner arm, then screw the tool in a little more and remove the pushrod pin from the auto tensioner. Remove the special tool and tighten the center bolt to 35 ft. lbs. (48 Nm).
  28.  
  29. Turn the crankshaft 1 / 4 turn counterclockwise, then clockwise until the timing marks are aligned.
  30.  
  31. Loosen the center bolt. Install special tool MD998767 on the tension pulley. Turn the tension pulley counterclockwise with a torque of 2.6 ft. lbs. (3.5 Nm) and tighten the center bolt to 35 ft. lbs. (48 Nm). Do not let the tension pulley turn with the bolt.
  32.  
  33. Turn the crankshaft two revolutions to the right and align the timing marks. After 15 minutes, measure the protrusion of the pushrod on the auto tensioner. The standard measurement is 0.150-0.177 inch (3.8-4.5mm). If the protrusion is out of specification, loosen the tension pulley, apply the proper torque to the belt and retighten the center bolt.
  34.  
  35. Install or connect the following:

    Crankshaft pulley. Tighten the mounting bolts to 18 ft. lbs. (25 Nm).
     
    Water pump. Tighten the mounting bolts to 6.5 ft. lbs. (8.8 Nm).
     
    Drive belts, then adjust
     
    Engine mount bracket
     
    Engine undercover
     
    Negative battery cable
     

  36.  

2.4L Engine



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Upper torque strut attaching bolts and strut
     
    Torque strut bracket from strut tower
     
    Torque strut bracket from engine
     
    Upper timing belt cover fasteners and cover

    Click image to see an enlarged view

    Fig. Upper torque strut and bracket mounting-2.4L engine



    Click image to see an enlarged view

    Fig. Upper and lower timing belt cover mounting-2.4L engine

     
    Right front wheel
     
    Accessory drive belt splash shield
     
    Accessory drive belts
     
    Crankshaft vibration damper with special Tools 1026 and 6287-A
     
    Lower torque strut
     
    Exhaust system from the exhaust manifold
     
    A/C pressure switch from the rear of the compressor housing
     

  4.  
  5. Lower the vehicle and support the engine with a suitable jack.

    Upper torque strut attaching bolts and remove strut
     
    Power steering pump and bracket. Set the pump aside. Do not disconnect the fluid lines from pump.
     
    Make sure the engine is properly supported, then remove the right engine mount through bolt
     
    Raise the engine with jack until you can access the engine support bracket bolts
     
    Engine support bracket
     
    Lower timing belt cover fasteners and cover
     

  6.  
  7. Rotate the crankshaft until the TDC mark on oil pump housing aligns with the TDC mark on crankshaft sprocket (trailing edge of sprocket tooth)
  8.  
  9. Loosen the timing belt tensioner lock bolt.
  10.  
  11. Insert a 6mm Allen wrench into the hexagon opening located on the top plate of the belt tensionerpulley. Rotate the top plate clockwise until there is enough slack in timing belt to allow for removal.
  12.  
  13. Remove or disconnect the following:
    WARNING
    If the timing belt was damaged due to incorrect alignment, you must replace the belt tensioner pulley and bracket as an assembly.



    Timing belt and camshaft sprockets.
     



    Crankshaft sprocket using Special Tool 6793 and insert C-4685-C2

    Click image to see an enlarged view

    Fig. View of the proper timing alignment marks for timing belt removal-2.4L engine



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    Fig. Timing belt tensioner mounting-2.4L engine



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    Fig. Removal and installation of the camshaft sprockets-2.4L engine



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    Fig. Removal of the crankshaft sprocket-2.4L engine



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    Fig. Installation of the crankshaft sprocket-2.4L engine



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    Fig. Make sure the marks are aligned before installing the timing belt-2.4L engine



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    Fig. View of the timing belt properly installed-2.4L engine



    Click image to see an enlarged view

    Fig. Timing belt tensioner adjustment-2.4L engine

     

  14.  

To install:


NOTE
The crankshaft sprocket is set to a pre-determined depth from the factory for correct timing belt tracking. If removed, use of Special Tool 6792 is required to set the sprocket to original installation depth. An incorrectly installed sprocket will result in timing belt and engine damage.

  1. Install or connect the following:
    WARNING
    Do not use an impact wrench to tighten camshaft sprocket bolts. Damage to the camshaft-to-sprocket locating dowel pin may occur.



    Crankshaft sprocket using Special Tool 6792
     



    Camshaft sprockets. Hold the sprockets with Special Tool 6847 while tightening center bolt to 85 ft. lbs. (115 Nm)
     

  2.  
  3. Set the crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing. Set the camshafts timing marks so that the exhaust camshaft sprocket is a 1/2 notch below the intake camshaft sprocket. Make sure the arrows on the camshaft sprockets are facing up.

    Timing belt, starting at the crankshaft, go around the water pump sprocket, idler pulley,camshaft sprockets and then around the tensioner
     
    Move the exhaust camshaft sprocket counterclockwise to align the marks and take up any timing beltslack.
     

  4.  
  5. Insert a 6mm Allen wrench into the hexagon opening located on the top plate of the belt tensionerpulley. Rotate the top plate counterclockwise. The tensioner pulley will move against the belt and the tensioner setting notch will eventually start to move clockwise. Watching the movement of the setting notch, continue rotating the top plate counterclockwise until the setting notch is aligned with the spring tang. Using the Allen wrench to prevent the top plate from moving, tighten the tensioner lock bolt to 18 ft. lbs. (25 Nm). The setting notch and spring tang should remain aligned after lock bolt is torqued.
  6.  
  7. Remove the Allen wrench and torque wrench.
    WARNING
    Repositioning the crankshaft to the TDC position must be done only during the clockwiserotation movement. If TDC is missed, rotate a further two revolutions until TDC is achieved. Do NOTrotate crankshaft counterclockwise as this will make verification of proper tensioner setting impossible.

  8.  
  9. Rotate the crankshaft clockwise 2 complete revolutions manually for seating of the timing belt,until the crankshaft is repositioned at the TDC position. Make sure that the camshaft and crankshaft timingmarks are in proper position.
  10.  
  11. Check if the spring tang is within the tolerance window. If the spring tang is within the tolerance window, the installation process is complete and nothing further is required. If the spring tang isnot within the tolerance window, repeat the previous 3 Steps.

    Click image to see an enlarged view

    Fig. Make sure the spring tang is within the tolerance window-2.4L engine

  12.  
  13. Install or connect the following

    Lower timing belt cover and tighten the retainers to 50 inch lbs. (6 Nm)
     
    Engine support bracket. Make sure the power steering pump is properly located in mounting location on bracket. Tighten the mount bracket bolts to 45 ft. lbs. (61 Nm).
     
    Lower engine into mounting position and right engine mount through bolt. Torque the bolt to 87 ft. lbs. (118 Nm)
     
    Power steering pump and bracket
     
    Upper torque strut attaching bolts
     
    Exhaust system to manifold
     
    A/C pressure switch connector
     
    Crankshaft vibration damper using thrust bearing washer and bolt from Installer Tool 6792 and torque the damper bolt to 100 ft. lbs. (135 Nm)
     
    Accessory drive belts
     
    Lower torque strut
     
    Accessory drive belt splash shield
     
    Right front wheel
     
    Upper timing belt cover and tighten fasteners to 50 inch lbs. (6 Nm)
     
    Torque strut bracket to engine
     
    Torque strut bracket to the strut tower
     
    Upper torque attaching bolts
     

  14.  
  15. Perform torque strut adjustment procedure, as follows:
    1. Remove the accessory drive belt splash shield.
    2.  
    3. Remove the pencil strut.
    4.  
    5. Loosen the upper and lower torque strut attaching bolt at the suspension crossmember andshock tower bracket.
    6.  
    7. Adjust the engine position by placing a floor jack on the forward edgeof the transmission bell housing

      Click image to see an enlarged view

      Fig. Position the floor jack properly to prevent upward lifting of the engine-2.4L engine

    8.  
    9. With the engine supported, remove the upper and lower torque strut attachment bolt(s) at shocktower bracket and suspension crossmember. Make sure the torque struts are free to move withinthe shock tower bracket and crossmember. Reinstall the torque strut bolt(s), but do not tighten yet.
    10.  
    11. Apply upward force, allowing the upper engine to rotate rearward until the distancebetween the center of the rearmost attaching bolt on the engine mount bracket (point A) and the centerof the hole on the shock tower bracket (point B) is 4.70 inch (119mm)
      WARNING
      Hold the engine in position with the jack until the upper and lower torque strut bolts are tightened.



      Click image to see an enlarged view

      Fig. Measure the distance between the center of the rearmost attaching bolt on the engine mount bracket (point A) and the center of the hole on the shock tower bracket (point B)-2.4L engine

    12.  
    13. With the engine held at the proper position, tighten both the upper and lower torque strut boltsto 85 ft. lbs. (115 Nm)
    14.  
    15. Remove the floor jack.
    16.  
    17. Install the pencil strut and tighten nuts to 43 ft. lbs. (58 Nm).
    18.  

  16.  
  17. Install the accessory drive belt splash shield.
  18.  

 
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