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1996 Dodge Neon L4-2.0L SOHC
Vehicle » Engine, Cooling and Exhaust » Engine » Timing Belt » Service and Repair » Timing Belt Removal and Installation
TIMING BELT REMOVAL AND INSTALLATION
TIMING BELT SERVICE
VALVE TIMING CHECK-TIMING BELT COVER INSTALLED
Remove number one spark plug.
Using a dial indicator; set number one cylinder to TDC on the compression stroke.
Remove the access plug from the outer timing belt cover.
Check the timing mark on the camshaft sprocket, it should align with the arrow on the rear belt cover.
REMOVAL
Remove accessory drive belts. Refer to Cooling System for procedure.
Raise vehicle on a hoist and remove right inner splash shield.
Remove crankshaft damper bolt. Remove damper using the large side of Special Tool 1026 and insert 6827.
Lower vehicle and place a jack under engine.
Remove right engine mount.
Remove right engine mount bracket.
Remove front half of timing belt cover.
Caution: Align camshaft and crankshaft timing marks before removing the timing belt.
Loosen timing belt tensioner screws and remove timing belt and tensioner.
SERVICING CAMSHAFT OIL SEALS/REPLACEMENT
CAUTION: Do not rotate the camshaft of crankshaft when timing belt is removed, damage to the engine may occur.
With timing belt removed, remove camshaft sprocket bolt.
Modify Special Tool C-4687-1 as shown in image above. Hold camshaft sprocket with modified tool while removing/installing bolt. Remove sprocket from camshaft.
Remove camshaft seal using Special C-4679
.
CAUTION: Do not nick shaft seal surface of bore.
Shaft seal lip surface must be free of varnish, dirt or nicks. Polish with 400 grit paper if necessary.
Install camshaft seal flush with cylinder head using Special Tool MD 998306.
Install camshaft sprocket retaining bolt. Hold camshaft sprocket with Special Tool C-4687-1 (shown in image above) and tighten bolt to 115 Nm (85 ft. lbs.) .
CAMSHAFT AND CRANKSHAFT TIMING PROCEDURE
TIMING BELT TENSIONER / TIMING BELT INSTALLATION
When tensioner is removed from the engine it is necessary to compress the plunger into the tensioner body.
Place the tensioner into a vise equipped with soft jaws and slowly compress the plunger.
CAUTION: Index the tensioner in the vise the same way it is installed on the engine. This is to ensure proper pin orientation when tensioner is installed on the engine.
When plunger is compressed into the tensioner body install a 1.9 mm (5/64) allen wrench or pin through the body and plunger to retain plunger in place until tensioner is installed.
Set crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing, then back off to 3 notches before TDC.
Set camshaft to TDC by aligning mark on sprocket with the arrow on the rear of timing belt cover.
Move crankshaft to 1/2 mark before TDC for belt installation.
Install timing belt. Starting at the crankshaft, go around the water pump sprocket and then around the camshaft sprocket.
Move crankshaft sprocket to TDC to take up belt slack. Install tensioner to block but do not tighten fasteners.
Using a torque wrench on the tensioner pulley apply 28 Nm (250 in. lbs.) of torque.
With torque being applied to the tensioner pulley move the tensioner up against the tensioner pulley bracket and tighten fasteners to 31 Nm (275 in. lbs.) .
Pull tensioner plunger pin. Pretension is correct when pin can be removed and installed.
Rotate crankshaft 2 revolutions and check the alignment of the timing marks.
Install front half of timing cover.
Install engine mount bracket.
Install Right engine mount.
Remove jack from under engine.
Install crankshaft damper using M12-1.75 150 mm bolt, washer, thrust bearing and nut from Special Tool 6792. Install crankshaft damper bolt an tighten to 142 Nm (105 ft. lbs.) .
Install accessory drive belts. Refer to Cooling System and Accessory Drive for procedure.
Raise vehicle on hoist and install right inner splash shield.
Perform relearn camshaft and crankshaft alignment procedure in Engine Miscellaneous of the DRB Scan Tool.
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