2005 CHRYSLER VOYAGER Engine

(16) Inserta6mmAllen wrench into the hexagon
opening located on the top plate of the belt tensioner
pulley (Fig. 121). Rotate the top plateCLOCKWISE
until there is enough slack in timing belt to allow for
removal.
(17) Remove timing belt.
CAUTION: If timing belt was damaged due to incor-
rect tracking (alignment), the belt tensioner pulley
and bracket must be replaced as an assembly
(Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT
TENSIONER & PULLEY - REMOVAL).
REMOVAL - CAMSHAFT SPROCKETS
(1) Disconnect negative battery cable.
(2) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(3) Hold camshaft sprockets with Special Tool 6847
while removing center bolts (Fig. 122).
REMOVAL - CRANKSHAFT SPROCKET
(1) Disconnect negative battery cable.(2) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
Fig. 119 Engine Mount Bracket
1 - ENGINE MOUNT BRACKET
2 - BOLTS - 61 N´m (45 ft. lbs.)
Fig. 120 Crankshaft and Camshaft Timing
1 - CAMSHAFT TIMING MARKS
2 - CRANKSHAFT TDC MARKS
3 - TRAILING EDGE OF SPROCKET TOOTH
Fig. 121 Timing Belt Tensioner
1 - LOCK BOLT
2 - TOP PLATE
9 - 66 ENGINE 2.4LRS
TIMING BELT AND SPROCKET(S) (Continued)

(3) Remove crankshaft sprocket using Special
Tools 6793 and insert C-4685-C2 (Fig. 123).
CLEANING
Do Not attempt to clean a timing belt. If contami-
nation from oil, grease, or coolants have occurred, the
timing belt should be replaced.
Clean all sprockets using a suitable solvent. Clean
all sprocket grooves of any debris.
INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET
CAUTION: The crankshaft sprocket is set to a pre-
determined depth from the factory for correct tim-
ing belt tracking. If removed, use of Special Tool6792 is required to set the sprocket to original
installation depth. An incorrectly installed sprocket
will result in timing belt and engine damage.
(1) Install crankshaft sprocket using Special Tool
6792 (Fig. 124).
(2) Install timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
INSTALLATION - CAMSHAFT SPROCKETS
(1) Install camshaft sprockets. Hold camshaft
sprockets with Special Tool 6847 while tightening
center bolts to 115 N´m (85 ft. lbs.) (Fig. 122).
(2) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
(3) Connect negative battery cable.
INSTALLATION - TIMING BELT
(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. 125).
CAUTION: Ensure that the arrows on both camshaft
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. 126).
(4) Move the exhaust camshaft sprocket counter-
clockwise (Fig. 126) to align marks and take up belt
slack.
Fig. 122 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 123 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL 6793
2 - SPECIAL TOOL C-4685±C2
3 - CRANKSHAFT SPROCKET
Fig. 124 Crankshaft Sprocket - Installation
1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL
RSENGINE 2.4L9-67
TIMING BELT AND SPROCKET(S) (Continued)

(5) Inserta6mmAllen wrench into the hexagon
opening located on the top plate of the belt tensioner
pulley. Rotate the top plateCOUNTERCLOCK-
WISE. The tensioner pulley will move against the
belt and the tensioner setting notch will eventually
start to move clockwise. Watching the movement of
the setting notch, continue rotating the top plate
counterclockwise until the setting notch is aligned
with the spring tang (Fig. 127). Using the allen
wrench to prevent the top plate from moving, torque
the tensioner lock bolt to 25 N´m (220 in. lbs.). Set-
ting notch and spring tang should remain aligned
after lock nut is torqued.
(6) Remove allen wrench and torque wrench.
NOTE: Repositioning the crankshaft to the TDC
position must be done only during the CLOCKWISE
rotation movement. If TDC is missed, rotate a fur-
ther two revolutions until TDC is achieved. DO NOT
rotate crankshaft counterclockwise as this will
make verification of proper tensioner setting impos-
sible.
Fig. 125 Camshaft Sprocket Alignment
1 - CAMSHAFT SPROCKET-EXHAUST
2 - CAMSHAFT SPROCKET-INTAKE
3 - 1/2 NOTCH LOCATION
Fig. 126 Timing Belt Installation
1 - CAMSHAFT TIMING MARKS 1/2 NOTCH LOCATION
2 - CRANKSHAFT AT TDC
3 - INSTALL BELT IN THIS DIRECTION
4 - ROTATE CAMSHAFT SPROCKET TO TAKE UP BELT SLACK
Fig. 127 Timing Belt Tension Adjustment
1 - ALIGN SETTING NOTCH WITH SPRING TANG
2 - TOP PLATE
3 - 6mm ALLEN WRENCH
4 - LOCK BOLT
5 - SETTING NOTCH
6 - SPRING TANG
9 - 68 ENGINE 2.4LRS
TIMING BELT AND SPROCKET(S) (Continued)

(7) Rotate the crankshaft CLOCKWISE two com-
plete revolutions manually for seating of the belt,
until the crankshaft is repositioned at the TDC posi-
tion. Verify that the camshaft and crankshaft timing
marks are in proper position (Fig. 128).
(8) Check if the spring tang is within the tolerance
window (Fig. 129). If the spring tang is within the
tolerance window, the installation process is complete
and nothing further is required. If the spring tang is
not within the tolerance window, repeat Steps 5
through 7.
(9) Install engine mount bracket to engine (Fig.
119).
(10) Install timing belt front covers and bolts
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT COVER(S) - INSTALLATION).
(11) Install air conditioning/generator belt ten-
sioner and pulley (Refer to 7 - COOLING/ACCES-
SORY DRIVE/BELT TENSIONERS -
INSTALLATION).
(12) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(13) Install crankshaft vibration damper (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).(14) Install accessory drive belts (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(15) Install drive belt splash shield.
(16) Install right front wheel.
(17) Connect make-up air hose to cylinder head
cover.
(18) Install air cleaner housing, upper cover, and
clean air tube.
TIMING BELT TENSIONER &
PULLEY
REMOVAL
(1) Remove the timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(2) Remove timing belt idler pulley (Fig. 130).
(3) Hold camshaft sprocket with Special Tool 6847
while removing bolt (Fig. 131). Remove both cam
sprockets.
(4) Remove rear timing belt cover fasteners and
remove cover from engine (Fig. 132).
(5) Remove lower bolt attaching timing belt ten-
sioner assembly to engine and remove tensioneras
an assembly(Fig. 133).
Fig. 128 Crankshaft and Camshaft Timing
1 - CAMSHAFT TIMING MARKS
2 - CRANKSHAFT TDC MARKS
3 - TRAILING EDGE OF SPROCKET TOOTH
Fig. 129 Timing Belt Tension Verification
1 - SPRING TANG
2 - TOLERANCE WINDOW
RSENGINE 2.4L9-69
TIMING BELT AND SPROCKET(S) (Continued)

INSTALLATION
(1) Align timing belt tensioner assembly to engine
and install lower mounting boltbut do not tighten
(Fig. 133). 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. 133).
(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.
Torque fasteners to values specified in (Fig. 132).
(4) Install timing belt idler pulley and torque
mounting bolt to 61 N´m (45 ft. lbs.) (Fig. 130).
(5) Install camshaft sprockets. Use Special Tool
6847 to hold sprockets (Fig. 131), torque bolts to 101
N´m (75 ft. lbs.).
(6) Install the timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
Fig. 130 Timing Belt Idler Pulley
1 - IDLER PULLEY
2 - BOLT
Fig. 131 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 132 Rear Timing Belt Cover Fasteners
1 - M6 BOLTS - 12 N´m (105 in. lbs.)
2 - M8 BOLTS - 28 N´m (250 in. lbs.)
3 - TIMING BELT TENSIONER
9 - 70 ENGINE 2.4LRS
TIMING BELT TENSIONER & PULLEY (Continued)

BALANCE SHAFTS AND
CARRIER ASSEMBLY
DESCRIPTION
The 2.4L engine is equipped with two nodular cast
iron balance shafts installed in a cast aluminum car-
rier attached to the lower cylinder block (Fig. 134).
OPERATION
The balance shafts are driven by the crankshaft
via a roller chain and sprockets. The balance shafts
are connected by helical gears. The dual counter
rotating shafts decrease second order vertical shak-
ing forces caused by component movement.
REMOVAL
BALANCE SHAFTS/CHAIN/SPROCKETS
NOTE: For service procedures requiring only tem-
porary relocation of carrier assembly refer to BAL-
ANCE SHAFT CARRIER procedure below.
(1) Drain engine oil.
(2) Remove the oil pan and pick-up tube (Refer to
9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL).
(3) If replacing crankshaft sprocket, remove oil
pump (Refer to 9 - ENGINE/LUBRICATION/OIL
PUMP - REMOVAL).
(4) Remove chain cover, guide and tensioner. Dis-
card pivot screw and adjuster screw. (Fig. 135).
(5) Remove screw retaining balance shaft drive
sprocket (Fig. 136). Remove chain and sprocket.
(6) Using two wide pry bars, work the crankshaft
sprocket back and forth until it is off the crankshaft-
shaft.
(7) Remove gear cover retaining stud (double
ended to also retain chain guide). Remove cover and
balance shaft gears (Fig. 137).
(8) Remove rear cover and balance shafts (Fig.
138).
(9) Remove four carrier to crankcase attaching
bolts to separate carrier from engine bedplate.
BALANCE SHAFT CARRIER
The following components will remain intact dur-
ing carrier removal: Gear cover, gears, balance shafts
and the rear cover (Fig. 134).
(1) Drain engine oil.
(2) Remove the oil pan and pick-up tube (Refer to
9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL).
(3) Remove chain cover, guide and tensioner (Fig.
135).
(4) Remove screw retaining balance shaft drive
sprocket (Fig. 136).
(5) Move balance shaft inboard through drive
chain sprocket. Sprocket will hang in lower chain
loop.
(6) Remove carrier to crankcase attaching bolts to
remove carrier.
Fig. 133 Timing Belt Tensioner/Bracket Assembly
1 - BOLT
2 - TENSIONER ASSEMBLY
3 - BOLT-INSTALL FOR PROPER ALIGNMENT
RSENGINE 2.4L9-71
TIMING BELT TENSIONER & PULLEY (Continued)

Fig. 134 Balance Shafts and Carrier Assembly
1 - SPROCKET 7 - GEARS
2 - TENSIONER 8 - GEAR COVER
3 - PLUG 9 - CHAIN COVER
4 - CARRIER 10 - SPROCKET
5 - REAR COVER 11 - GUIDE
6 - BALANCE SHAFTS 12 - CHAIN
Fig. 135 Chain Cover, Guide and Tensioner
1 - STUD
2 - TENSIONER (ADJUSTER)
3 - GEAR COVER
4 - ADJUSTER SCREW
5 - SHOULDERED PIVOT SCREW
6 - CHAIN COVER (CUTAWAY)
7 - GUIDEFig. 136 Drive Chain and Sprockets
1 - NICKEL PLATED LINK AND MARK
2 - GEAR/SPROCKET SCREWS
3 - NICKEL PLATED LINK AND DOT
9 - 72 ENGINE 2.4LRS
BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued)

INSTALLATION
BALANCE SHAFT INSTALLATION/TIMING
Balance shaft and carrier assembly installation is
the reverse of the removal procedure.During instal-
lation crankshaft-to-balance shaft timing must
be established. Refer to Timing procedure in
this section.
(1) With balance shafts installed in carrier (Fig.
134) position carrier on crankcase and install four
attaching bolts and tighten to 54 N´m (40 ft. lbs.).
(2) Turn balance shafts until both shaft key ways
are up, parallel to vertical centerline of engine.
Install short hub drive gear on sprocket driven shaft
and long hub gear on gear driven shaft. After instal-
lation gear and balance shaft keyways must be up
with gear timing marks meshed as shown in (Fig.
139).
(3) Install gear cover and tighten double ended
stud/washer fastener to 12 N´m (105 in. lbs.).
(4) Align flat on balance shaft drive sprocket to the
flat on crankshaft (Fig. 140).
(5) Install balance shaft drive sprocket on crank-
shaft using Special Tool 6052 (Fig. 141).
Fig. 137 Gear Cover and Gears
1 - STUD (DOUBLE ENDED)
2 - DRIVE GEAR
3 - DRIVEN GEAR
4 - CARRIER DOWEL
5 - GEAR(S)
6 - GEAR COVER
Fig. 138 Balance Shaft - Removal/Installation
1 - REAR COVER
2 - CARRIER
3 - BALANCE SHAFT
Fig. 139 Gear Timing
1 - KEY WAYS UP
2 - GEAR ALIGNMENT DOTS
RSENGINE 2.4L9-73
BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued)