How to Replace timing belt on Chrysler Voyager 2.4 2003-

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 – hrs

Remove & install

1,50

Special Tools

• Crankshaft pulley puller – No.1026.
• Crankshaft pulley installer – No.6792.
• Insert for puller – 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 ‘UP’ 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 ‘UP’ 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.