1995 Dodge Neon Timing Belt Replacement.pdf

 1995 Dodge Neon Timing Belt Replacement

Removal (Hydraulic Tensioner) 1. Remove No. 1 spark plug. Using dial indicator, set number one cylinder to TDC of compression stroke. Remove access plug from top of timing belt cover. See Fig. 1 . Ensure timing mark on camshaft aligns with mark on rear cover. See Fig. 2 . 2. Disconnect negative battery cable. Remove accessory drive belts. Raise vehicle and remove right inner splash shield. See Fig. 3 . Remove crankshaft damper bolt. Use gear puller to remove crankshaft damper. 3. Lower vehicle and place a jack under engine to support weight. Remove right engine mount. On Breeze and Stratus, remove generator (with wiring attached) and bracket, and secure out of way. On Neon, remove power steering pump with hoses attached, and secure out of way. On all models, remove right engine mount bracket from engine. See Fig. 4 . 4. Remove front timing belt cover. See Fig. 1 . Rotate crankshaft so that timing marks are aligned.

See Fig. 2 . Loosen timing belt tensioner bolts. If reusing timing belt, mark arrow on belt to indicate direction of rotation. Remove timing belt and tensioner. DO NOT loosen, tighten, or remove tensioner pulley pivot bolt. CAUTION: To prevent pistons from hitting valves, do not rotate camshaft or crankshaft after removing the timing belt. NOTE: When tensioner is removed from engine, it is necessary to compress plunger into tensioner body. Index tensioner in vise the same way it is installed on engine to ensure proper pin orientation when tensioner is installed on engine. Timing Belt Tensioner Bracket Precaution CAUTION: The following revised information regarding the tensioner pulley pivot bolt is from Chrysler technical service bulletin 09-06-96; March 29, 1996. On models with hydraulic timing belt tensioner, do not loosen, tighten, or remove timing belt tensioner pivot bolt. Bolt is installed at factory with special threadlocking compound that is not reusable. If tensioner pivot bolt is disturbed, entire bracket assembly must be replaced. The tensioner pulley center bolt MAY be removed and installed. Inspection Check belt teeth for damage or oil contamination. Inspect belt for glossy, hardened or non-elastic surface. Ensure the belt is not cracked, separated or showing canvas fiber. Inspect all sprockets for damage. Check tensioner pulley and idler pulley for signs of grease leakage or roughness in rotation. Replace components if damaged. Installation (Hydraulic Tensioner)

1. Place tensioner in soft-jawed vise and slowly compress plunger. See Fig. 5 . When plunger is compressed into tensioner body, install a 5/16″ (1.9 mm) hex wrench or locking pin through body and plunger to hold plunger in place until tensioner is installed. 2. Set crankshaft sprocket to TDC by aligning sprocket with arrow on oil pump housing, then back off to 3 notches before TDC. 3. Set camshaft to TDC by aligning mark on sprocket with arrow on rear of timing belt cover. See Fig. 2 . Move crankshaft to 1/2 notch mark before TDC for belt installation. See Fig. 6 . Install timing belt by starting at crankshaft, then around water pump sprocket and then camshaft sprocket. 4. Move crankshaft sprocket to TDC to take up belt slack.

Install tensioner to block, but do not final tighten bolts. Using a torque wrench on tensioner pulley, apply 21 ft. lbs. (28 N. m) of torque in clockwise direction. With torque applied to tensioner pulley, move the tensioner up against the tensioner pulley bracket. Final tighten tensioner bolts. See Fig. 1 . 5. Pull tensioner plunger locking pin. Pretension is correct when pin can be removed and installed. Rotate crankshaft 2 revolutions. Check alignment of the timing marks. Install front timing belt cover. Install engine mount bracket. Install generator and bracket (Breeze and Stratus) or power steering pump (Neon). 6. Install right engine mount. Remove jack from under engine. Install crankshaft damper, and tighten bolt to specification. See TORQUE SPECIFICATIONS . 7. Raise vehicle on hoist. Install right inner splash shield. Lower vehicle. Install accessory drive belts. Adjust drive belts to proper tension. 8. On Neon, connect scan tool to Data Link Connector (DLC) under lower left edge of instrument panel. Follow scan tool manufacturer’s instructions to access the cam/crank relearn procedure. Perform cam/crank relearn procedure.