Monday, February 13, 2012

How to replace Timing Belt & Sprockets on 2001 Dodge neon?

Timing belt got loose,timing belt sprockets issue,timing belt replacement is over due.

In this cases the timing belt and timing belt sprockets needs to be inspected and replaced.

The details to complete this task is as follows :------


Removal & Installation



2.0L (VIN F) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2. 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
  3. Rotate the crankshaft clockwise to align the camshaft timing marks. Always turn the crankshaft in the forward direction only.
  4. 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.
  5. Move the tension pulley towards the water pump and remove the timing belt.
  6. 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.
  7. Mark the direction of rotation on the timing belt -B- with a arrow.
  8. Loosen the center bolt on the tensioner and remove the belt.
  9. 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.



    Click image to see an enlarged view
    Fig. Notice the timing mark on the oil pump drive sprocket-2.0L (VIN F) engines
    Notice the timing mark on the oil pump drive sprocket-2.0L (VIN F) engines

    Click image to see an enlarged view
    Fig. Timing belt -B- timing marks locations-2.0L (VIN F) engines
    Timing belt -B- timing marks locations-2.0L (VIN F) engines
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. Install the cylinder head cover.
  3. 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).
  4. Align the timing marks on the crankshaft sprocket -B- and the balance shaft.
  5. 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.
  6. 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.
  7. 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).
  8. 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.
  9. Install the auto tensioner on the engine.
  10. Align the timing marks on the camshaft sprocket, crankshaft sprocket and the oil pump sprocket.
  11. 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.
  12. 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
  13. Turn the tension pulley so the pinholes are at the bottom. Press the pulley lightly against the timing belt.
  14. 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).
  15. Turn the crankshaft 1 / 4 turn counterclockwise, then clockwise until the timing marks are aligned.
  16. 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.
  17. 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.
  18. 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


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This details will help.
Thanks.

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