1995 Dodge Neon Timing Belt Installation & Removal

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.

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.

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