How to Replace timing belt on Chrysler Voyager 2.4 2003-

Chrysler

Replacement Interval Guide

  • Chrysler recommend replacement every 97,500 miles or 78 months.
  • The previous use and service history of the vehicle must always be taken into account.

Check For Engine Damage

CAUTION: This engine has been identified as an INTERFERENCE engine in which the possibility of valve-to-piston damage in the event of a timing belt failure is MOST LIKELY to occur. A compression check of all cylinders should be performed before removing the cylinder head.

Repair Times ‚Äď hrs

Remove & install1,50

Special Tools

  • Crankshaft pulley puller ‚Äď No.1026.
  • Crankshaft pulley installer ‚Äď No.6792.
  • Insert for puller ‚Äď No.6827-A.
 

Special Precautions

  • Disconnect battery earth lead.
  • DO NOT turn crankshaft or camshaft when timing belt removed.
  • Remove spark plugs to ease turning engine.
  • Turn engine in normal direction of rotation (unless otherwise stated).
  • DO NOT turn engine via camshaft or other sprockets.
  • Observe all tightening torques.

 

Removal

  1. Raise and support front of vehicle.
  2. Remove:
      • RH front wheel.
      • RH splash guard.
      • Auxiliary drive belts.
      • Air filter housing and hoses.
      • Crankshaft pulley bolt¬†[1]¬†.
      • Crankshaft pulley¬†[2]¬†. Use tool Nos.1026 & 6827-A.
      • Alternator and bracket.
      • Auxiliary drive belt tensioner.
      • Timing belt covers¬†[3]¬†&¬†[4]¬†.
  3. Support engine.
  4. Remove:
      • RH engine mounting bolts¬†[5]¬†,¬†[6]¬†&¬†[7]¬†.
      • RH engine mounting¬†[8]¬†.
      • RH engine mounting bracket bolts¬†[9]¬†.
      • RH engine mounting bracket¬†[10]¬†.
  5. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure timing marks aligned¬†[11]¬†&¬†[12]¬†.NOTE: Arrows and ‚ÄėUP‚Äô marks on camshaft sprockets must face upwards.
  6. Slacken tensioner pulley bolt [13] .
  7. Turn tensioner pulley clockwise to release tension on belt. Use 6 mm Allen key [14] .
  8. Remove timing belt.

Installation

  1. Ensure timing marks aligned [11] & [12] .
  2. Turn exhaust camshaft sprocket 1/2 tooth clockwise [15] .
  3. Fit timing belt in anti-clockwise direction, starting at crankshaft sprocket.NOTE: Arrows and ‚ÄėUP‚Äô marks on camshaft sprockets must face upwards.
  4. Turn exhaust camshaft sprocket slowly anti-clockwise until timing marks aligned [12] .
  5. Turn tensioner pulley anti-clockwise until notch aligned with spring [16] . Use 6 mm Allen key [14] .
  6. Tighten tensioner pulley bolt [13] . Tightening torque: 25 Nm.
  7. Turn crankshaft two turns clockwise. Ensure timing marks aligned [11] & [12] .
  8. Ensure tensioner pulley spring is positioned within area shown [17] . If not: Repeat tensioning procedure.
  9. Install components in reverse order of removal.
  10. Fit crankshaft pulley [2] . Use tool No.6792.
  11. Tighten crankshaft pulley bolt [1] . Tightening torque: 142 Nm.
  12. Tighten RH engine mounting bracket bolts [9] . Tightening torque: 61 Nm.
  13. Tighten RH engine mounting bolts [5] & [6] . Tightening torque: 68 Nm.
  14. Tighten RH engine mounting bolts [7] . Tightening torque: 54 Nm.
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Bent Valves
Timing Tools?
Misconception
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Bent Valves

What happens when your chain or belt breaks. 

The timing of course becomes way off. Your crankshaft will always spin making the pistons move up and down. However the valves will remain in the position they were in when the belt or chain stopped working. 

Half of the valves will be stuck open and in the way of the pistons. Not all engines, but most. The piston out of valve time will smash right into the open valve and bend the, The only way to fix that is to remove the head and place those valves. 

If you think your valves might have been damaged.

Remove all the spark plugs, valve covers. With both valves in the closed position insert a compression tester hose in place of the spark plug and inject air into the hose and see if the cylinder can hold air. If both valve are closed and air can not be held, chances are you have bent valves.   

 

Timing Tools?

Do you need special tools to time your engine? Not always, on all my post I'll indicate that in each post if you do or not. 

But what are these special tools? Normally you would just line up some marks on the cam and crank gears and simply be done with it. However when these tools are needed they are very very important. 

The last one I did was a 2013 Range Rover 2.0 Turbo with dual cams. There were not timing marks at all. 

There is a small threaded plug on the back of the engine that I removed to insert a special threaded pin that would rest up against the weight of the crankshaft to prevent for DTC of the #1 piston. No further clockwise rotation would be possible. At that point I installed the supplied crankshaft lock by removing the starter. 

Then you line up the back of both camshafts to a notch in each camshafts to each other that a flat tool connects to each cam so they are in line with each other. But first you would make sure both intake and exhaust valves are closed DTC of the cams. 

And the last tool was to lineup the crankshaft position sensor. 

 

Misconception

The most important thing in any major engine work is to rotate the engine by hand at least two complete rotations. And do it easy and slow and with the spark plugs removed. 

Why remove the spark plugs? you may ask. Simple, with the plugs in place you'll be creating compression, making the engine harder to turn by hand and perhaps giving you the misconception of valves hitting the pistons or is it compression.  

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