PT Cruiser 2006-2007

Timing Belt & Sprockets

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Removal & Installation



Camshaft Sprockets
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove upper and lower front timing belt covers.
  4.  
  5. Remove timing belt.
  6.  
  7. Use Special Tool 6847 to hold camshaft sprockets while removing the sprocket bolt(s).
  8.  
  9. Remove camshaft sprocket(s).

    Click image to see an enlarged view

    Fig. Camshaft sprocket removal and installation

  10.  

To install:


CAUTION
Do not use an impact wrench to tighten camshaft sprocket bolts. Damage to the camshaft-to-sprocket locating dowel pin may occur.

  1. Install camshaft sprockets. Hold sprockets with Special Tool 6847 while tightening center bolt to 85 ft. lbs. (115 Nm).
  2.  
  3. Install the timing belt.
  4.  
  5. Install the upper and lower front timing belt covers.
  6.  

Crankshaft Sprocket
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove upper and lower front timing belt covers.
  4.  
  5. Remove the timing belt.
  6.  
  7. Remove the crankshaft sprocket using Special Tool 6793 and insert C-4685-C2.

    Click image to see an enlarged view

    Fig. Crankshaft sprockets removal and installation

  8.  

To install:


WARNING
The crankshaft sprocket is set to a predetermined 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 the crankshaft sprocket using Special Tool 6792.
  2.  
  3. Install the timing belt.
  4.  
  5. Install the upper and lower front timing belt covers.
  6.  

Timing Belt
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the A/C refrigerant using approved equipment. Refer to the Heating & Air Conditioning Section.
  4.  
  5. Remove or disconnect the following to remove the upper timing cover:

    The negative battery cable
     
    The upper torque strut bolts and set the strut aside
     
    The A/C lines at the junction block near the upper timing belt cover, if equipped with a turbocharger
     
    The upper cover bolts and the cover
     

  6.  
  7. Remove or disconnect the following to remove the lower timing cover:

    The right front wheel and inner splash shield
     
    The accessory drive belts
     
    The crankshaft damper
     
    The lower torque strut
     
    The exhaust system from the manifold
     
    The A/C compressor switch
     
    The upper torque strut and bracket
     
    The upper radiator support crossmember
     
    The power steering pump and bracket without disconnecting the lines
     
    The right engine mount through bolt after supporting the engine
     
    The engine support bracket
     
    The lower cover bolts and the cover
     

  8.  
  9. Rotate the crankshaft until the Top Dead Center (TDC) mark on the oil pump housing aligns with the TDC mark on the crankshaft sprocket.
  10.  
  11. Loosen the belt tensioner lock bolt.
  12.  
  13. Install a 6mm Allen wrench into the tensioner. Rotate the tensioner counterclockwise while pushing on the wrench until it slides into the locking hole.
  14.  
  15. Remove the timing belt.

    Click image to see an enlarged view

    Fig. Camshaft and crankshaft alignment marks-2.4L engine

  16.  

To install:

Click image to see an enlarged view

Fig. Install the belt tensioner



Click image to see an enlarged view

Fig. Proper timing belt routing

  1. Set the crankshaft sprocket at TDC by aligning the sprocket with the arrow on the oil pump housing.
  2.  
  3. Set the camshafts timing marks so that the exhaust camshaft sprocket is a 1 / 2 notch below the intake camshaft sprocket.
  4.  
  5. Install the timing belt by starting at the crankshaft. Go around the water pump sprocket, idler pulley, camshaft sprockets and the tensioner.
  6.  
  7. Move the exhaust camshaft sprocket counterclockwise to align the marks and to remove any slack.
  8.  
  9. Insert a 6mm Allen wrench into the tensioner opening on the top plate of the tensioner pulley.
  10.  
  11. Rotate the top plate counterclockwise. The pulley will move against the belt and the tensioner setting notch will start to move clockwise. Continue to move the top plate counterclockwise until the setting notch is aligned with the spring tang.
  12.  
  13. Using the Allen wrench, to prevent the top plate from moving, tighten the tensioner lock bolt to 220 inch lbs. (25 Nm). Make sure the setting notch and spring tang are still aligned after the lock nut is tighten (if not repeat the procedure).
  14.  
  15. Remove the wrench from the belt tensioner.
    NOTE
    When repositioning the crankshaft to the TDC position, this must be done during the clockwise rotation movement. If the TDC is missed, rotate a further two full turns until TDC is reached. Do not rotate the crankshaft counterclockwise as this will result in improper tensioner settings.

  16.  
  17. Rotate the crankshaft 2 full revolutions and verify that the TDC marks are properly aligned.
  18.  
  19. Check the spring tang is within the tolerance window, if not repeat the previous two steps.
  20.  
  21. Install or connect the following:

    The lower timing belt cover and torque the bolts to 50 inch lbs. (6 Nm).
     
    The upper timing belt cover and torque the bolts to 50 inch lbs. (6 Nm).
     
    The A/C lines at the junction block near the upper timing belt cover, if equipped with a turbocharger
     
    The right engine support bracket and reposition the power steering pump. Torque the bracket bolts to 45 ft. lbs. (61 Nm).
     
    The right engine mount through bolt and torque it to 87 ft. lbs. (118 Nm)
     
    The upper radiator support crossmember
     
    The torque strut bracket
     
    The upper torque strut
     
    The A/C lines and pressure switch
     
    The exhaust system to the manifold
     
    The crankshaft damper
     
    The accessory drive belts
     
    The lower torque strut
     
    The right splash shield and wheel
     
    The negative battery cable
     

  22.  
  23. Recharge the A/C system.
  24.  
  25. Perform the camshaft/crankshaft synchronization procedure.
  26.  

 
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