1996 CHRYSLER VOYAGER Service Manual

CAUTION: If timing belt was damaged due to incor-
rect tracking (alignment), the belt tensioner assem-
bly must be replace. Refer to Timing Belt Tensioner
Assembly Removal and Installation procedure out-
lined in this section.
INSTALLATION
(1) Set crankshaft sprocket to TDC by aligning
the sprocket with the arrow on the oil pump housing.
(2) Set camshafts timing marks so that the
exhaust camshaft sprocket is a 1/2 notch below the
intake camshaft sprocket (Fig. 61).
CAUTION: Ensure that the arrows on both cam-
shaft sprockets are facing up.
(3) Install timing belt. Starting at the crankshaft,
go around the water pump sprocket, idler pulley,
camshaft sprockets and then around the tensioner
(Fig. 62).
(4) Move the exhaust camshaft sprocket counter-
clockwise (Fig. 62) to align marks and take up belt
slack.
NOTE: A new tensioner is held in the wound posi-
tion by a pull pin.
(5) Remove the pull pin or Allen wrench from the
belt tensioner.
(6) Once timing belt has been installed and ten-
sioner released, rotate crankshaft two (2) complete
revolutions. Verify that the TDC marks on crank-
shaft and timing marks on the camshafts are aligned
as shown in (Fig. 60).
(7) Install right engine mount and support
bracket. Refer to Removal and Installation procedure
in this section.
(8) Install upper timing belt cover bolts 4.5 N´m
(40 in. lbs.).
(9) Install the lower timing belt cover bolts 4.5
N´m (40 in. lbs.).
(10) Install crankshaft damper. Refer to procedure
outlined in this section.
(11) Install accessory drive belts. Refer to Group 7,
Cooling System.
(12) Install right inner splash shield.
(13) Install right front wheel.
Fig. 60 Crankshaft and Camshaft Timing
Fig. 61 Camshaft Sprocket Alignment
NS2.4L ENGINE 9 - 39
REMOVAL AND INSTALLATION (Continued)

TIMING BELT TENSIONER ASSEMBLY
REMOVAL
(1) Remove timing belt. Refer to Removal and
Installation procedure in this section.
(2) Remove timing belt idler pulley.
(3) Hold camshaft sprocket with Special Tools
C-4687 and C-4687-1 Adapter, while removing bolt
(Fig. 63). Remove both cam sprockets.(4) Remove rear timing belt cover fasteners and
remove cover from engine (Fig. 64).
(5) Remove lower bolt attaching timing belt ten-
sioner assembly to engine and remove tensioneras
an assembly(Fig. 65).INSTALLATION
(1) Align timing belt tensioner assembly to engine
and install lower mounting boltbut do not tighten
(Fig. 65). To properly align tensioner assemblyÐin-
stall one of the engine bracket mounting bolts (M10)
5 to 7 turns into the tensioner's upper mounting loca-
tion (Fig. 65).
(2) Torque the tensioner's lower mounting bolt to
61 N´m (45 ft. lbs.). Remove the upper bolt used for
tensioner alignment.
(3) Install rear timing belt cover and fasteners.
(4) Install timing belt idler pulley and tighten
mounting bolt to 61 N´m (45 ft. lbs.).
(5) Install camshaft sprockets. Use Special Tools
C-4687 and C-4687-1 Adapter to hold camshaft
sprockets (Fig. 63) and tighten attaching bolts to 101
N´m (75 ft. lbs.).
(6) Install timing belt. Refer to procedure outlined
in this section.
Fig. 62 Timing BeltÐInstallation
Fig. 63 Camshaft SprocketsÐRemoval/Installation
Fig. 64 Rear Timing Belt Cover Fasteners
9 - 40 2.4L ENGINENS
REMOVAL AND INSTALLATION (Continued)

CAMSHAFT OIL SEALÐFRONT
REMOVAL
(1) Remove front timing belt covers and timing
belt. Refer to procedures outlined in this section.
(2) Hold camshaft sprocket with Special Tools
C-4687 and 4687-1 while removing center bolt (Fig.
66).
(3) Remove camshaft seal using Special Tool
C-4679-A (Fig. 67).
CAUTION: Do not nick shaft seal surface or seal
bore
INSTALLATION
(1) Shaft seal surface must be free of varnish, dirt
or nicks. Polish with 400 grit paper if necessary.
(2) Install camshaft seal into cylinder head using
Special Tool MD-998306 until flush with head (Fig.
68).
(3) Install camshaft sprocket. While holding
sprocket with Special Tools C-4687 and 4687-1,
tighten center bolt to 101 N´m (75 ft. lbs.) (Fig. 66).
Fig. 65 Timing Belt Tensioner AssemblyÐRemoval/
Installation
Fig. 66 Camshaft SprocketÐRemoval/Installation
Fig. 67 Camshaft Oil SealÐRemoval With C-4679±A
Fig. 68 Camshaft SealÐInstallation
NS2.4L ENGINE 9 - 41
REMOVAL AND INSTALLATION (Continued)

CRANKSHAFT OIL SEALÐFRONT
REMOVAL
(1) Using Special Tool 1026 and Insert 6827-A,
remove crankshaft damper (Fig. 69).
(2) Remove outer timing belt cover and timing
belt. Refer to procedures outlined in this section.
(3) Remove crankshaft sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 70).
CAUTION: Do not nick shaft seal surface or seal
bore.
(4) Using Tool 6771 to remove front crankshaft oil
seal (Fig. 71). Be careful not to damage the seal sur-
face of cover.
INSTALLATION
(1) Install new seal by using Tool 6780 (Fig. 72).
(2) Place seal into opening with seal spring
towards the inside of engine. Install seal until flush
with cover.(3) Install crankshaft sprocket (Fig. 73). Using
Special Tool 6792.
(4) Install timing belt and timing belt covers. Refer
to Timing System Section for timing belt covers and
belt.
(5) Install crankshaft damper (Fig. 74). Use thrust
bearing/washer and 12M 1.75 x 150 mm bolt from
Special Tool 6792. Install crankshaft damper bolt and
tighten to 142 N´m (105 ft. lbs.)
Fig. 69 Crankshaft DamperÐRemoval
Fig. 70 Crankshaft SprocketÐRemoval
Fig. 71 Front Crankshaft Oil SealÐRemoval
Fig. 72 Front Crankshaft Oil SealÐInstallation
9 - 42 2.4L ENGINENS
REMOVAL AND INSTALLATION (Continued)

CRANKSHAFT OIL SEALÐREAR
REMOVAL
(1) Insert a 3/16 flat bladed screwdriver between
the dust lip and the metal case of the crankshaft
seal. Angle the screwdriver (Fig. 75) through the dust
lip against metal case of the seal. Pry out seal.
CAUTION: Do not permit the screwdriver blade to
contact crankshaft seal surface. Contact of the
screwdriver blade against crankshaft edge (cham-
fer) is permitted.
Fig. 73 Crankshaft SprocketÐInstallation
Fig. 74 Crankshaft DamperÐInstallationFig. 75 Rear Crankshaft Oil SealÐRemoval
NS2.4L ENGINE 9 - 43
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
CAUTION: If burr or scratch is present on the
crankshaft edge (chamfer), cleanup with 400 grit
sand paper to prevent seal damage during installa-
tion of new seal.
NOTE: When installing seal, no lube on seal is
needed.
(1) Place Special Tool 6926-1 on crankshaft. This is
a pilot tool with a magnetic base (Fig. 76).
(2) Position seal over pilot tool. Make sure you can
read the wordsTHIS SIDE OUTon seal (Fig. 76).
Pilot tool should remain on crankshaft during instal-
lation of seal. Ensure that the lip of the seal is facing
towards the crankcase during installation.
CAUTION: If the seal is driven into the block past
flush, this may cause an oil leak.
(3) Drive the seal into the block using Special Tool
6926-2 and handle C-4171 (Fig. 77) until the tool bot-
toms out against the block (Fig. 78).
Fig. 76 Rear Crankshaft Seal and Special Tool
6926-1
Fig. 77 Crankshaft Seal Special Tool 6926-2
Fig. 78 Rear Crankshaft SealÐInstallation
9 - 44 2.4L ENGINENS
REMOVAL AND INSTALLATION (Continued)