Engine - Timing Belt Frayed/Shredded/Broken
NO: O9-11-96 Rev. AGROUP: Engine
DATE: Nov. 29, 1996
SUBJECT:
2.4L Timing Belt Service
THIS BULLETIN SUPERCEDES TECHNICAL SERVICE BULLETIN 09-11-96, DATED NOV. 3, 1996 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE TORQUE SPECIFICATION FOR STEP 8 HAS BEEN CHANGED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1996 (GS) Chrysler Voyager (European Market)
1996 (JA) Breeze/Cirrus/Stratus
1996 (JX) Sebring Convertible
1996 (NS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO 2.4L ENGINES WITH MECHANICAL TENSIONERS AND ENGINE BUILD CODES OF 087 THROUGH 153.
The engine code is a 14 position code located on a bar code label. Passenger cars have a blue label affixed to the upper timing belt cover and Minivans have an orange label affixed to the backside of the intake manifold (Figure 1). The date is the 6th, 7th, and 8th position of the 14 position code.
SYMPTOM/CONDITION:
Timing belt damaged or worn excessively on the forward edge due to improper belt alignment. This condition is limited to engines with mechanical tensioners only.
DIAGNOSIS:
Remove the upper belt cover and inspect the timing belt. If the belt is shredded, frayed or broken, perform the Repair Procedure.
NOTE:
A BROKEN TIMING BELT WILL NOT CAUSE PISTON OR VALVE DAMAGE.
PARTS REQUIRED:
1 04897054AA Timing Belt Tensioner Assembly
1 04694228 Timing Belt Idler Pulley
1 04621844 Timing Belt
REPAIR PROCEDURE:
This repair involves replacing the tensioner assembly, idler pulley and timing belt.
1. Refer to the appropriate service manual and follow timing belt removal procedures.
2. Remove the timing belt idler pulley.
3. Hold the camshaft sprocket with Special Tool 0-6847 while removing the camshaft sprocket bolt. Remove both sprockets.
4. Remove rear timing belt cover fasteners and remove cover from engine (Figure 1).
5. Remove the lower bolt attaching the timing belt tensioner assembly to the engine. Remove the tensioner and bracket assembly (Figure 2).
6. Install the new tensioner assembly to the engine and install the lower mounting bolt, but do not tighten (Figure 2). The tensioner must be aligned properly prior to torquing the lower bolt. Install an upper mounting bolt several turns into the upper mounting location and torque the lower bolt to 61 Nm (45 ft. lbs.). Remove the upper bolt used for alignment.
NOTE:
THE NEW TENSIONER MUST BE INSTALLED AS AN ASSEMBLY WITH ITS BRACKET ATTACHED. DO NOT SEPARATE THE NEW TENSIONER FROM ITS MOUNTING BRACKET.
7. Install the rear timing belt cover and fasteners.
8. Install the timing belt idler pulley and torque the mounting bolt to **61 Nm (45 ft. lbs.).
9. Install the camshaft sprockets and torque the mounting bolts to 101 Nm (75 ft. lbs.).
10. Install the timing belt and follow the procedures in the applicable service manual for timing the engine and re-installation of the remaining components.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 09-10-02-90 2.1 Hrs.
FAILURE CODE: P8 - New Part