1996 Dodge Intrepid REMOVAL & INSTALLATION TIMING BELT

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Filed Under (Dodge) by admin on 08-12-2010

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CAUTION: The following procedure can only be used if camshaft sprockets have NOT been loosened or removed. If camshaft sprockets have been removed, special tools and timing procedure are required. 1. Disconnect negative battery cable from jumper terminal. Remove upper radiator crossmember (may also be referred to as the engine compartment support). Remove electric cooling fan module with fans. 2. Remove accessory drive belts. Hold crankshaft damper stationary while removing center bolt. See Fig. 1 . Use gear puller to remove crankshaft damper. Remove the A/C belt guide/lift bracket. 3. Remove lower timing belt cover. Remove stamped steel (right side) timing belt cover. DO NOT remove the sealer on the stamped steel cover, as it is reusable. 4. Remove cast (left side) timing belt cover. If reusing old timing belt, mark belt direction of rotation for reinstallation. CAUTION: Align camshaft sprockets between marks on rear belt covers before removing timing belt, or damage to valves and pistons may occur. CAUTION: When aligning timing marks, always rotate engine by turning crankshaft. Failure to do so will result in valve and/or piston damage. 5. Rotate crankshaft to align crankshaft sprocket timing mark with TDC mark on oil pump housing. Align camshaft sprockets with marks on rear covers. See Fig. 2 and Fig. 3 . CAUTION: When timing belt tensioner is removed from engine, always store tensioner with plunger facing up. 6. Remove timing belt tensioner. See Fig. 1 . Store with plunger facing up. Remove timing belt.

1996 Dodge Intrepid NO CRANK REFERENCE SIGNAL AT PCM

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Filed Under (Dodge) by admin on 07-12-2010

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For connector terminal ID, see CONNECTOR IDENTIFICATION DIRECTORY table. For wiring diagram, see L – WIRING DIAGRAMS article. 1. If referenced to this test from TEST NS-1A, go to next step. If not referenced to this test from TEST NS- 1A, turn ignition off. Attempt to start engine. Using scan tool, read camshaft signal state while attempting to start engine. Go to next step. 2. If camshaft signal is detected, go to next step. If camshaft signal is not detected, go to TEST TC-1A – NO CAM SIGNAL AT PCM . 3. Using scan tool, read engine RPM and attempt to start engine. If scan tool displayed more than 10 RPM when engine is cranked, go to next step. If scan tool display is 10 RPM or less when engine is cranked, go to step 6 . 4. Condition to set trouble code is not present at this time. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If related wiring and connectors were repaired, perform TEST VER-2A – ROAD TEST VERIFICATION . 5. Start engine. Wiggle wiring harness between Camshaft Position (CMP) sensor and Crankshaft Position (CKP) sensor to Powertrain Control Module (PCM). If engine misses or stalls, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A – ROAD TEST VERIFICATION . If engine did not miss or stall, see INACTIVE TROUBLE CODE CONDITION . Test is complete. Perform TEST VER-2A – ROAD TEST VERIFICATION .

2000 Dodge Intrepid Timing Chain REMOVAL

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Filed Under (Dodge) by admin on 21-09-2010

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1. Remove upper intake manifold. 2. Remove cylinder head covers, crankshaft damper, and timing chain cover. CAUTION: When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage. Fig. 70 3. Align crankshaft sprocket timing mark to mark on oil pump housing (Fig. 70). The mark on oil pump housing is 60° ATDC of #1 cylinder. CAUTION: When the timing chain is removed and the cylinder heads are still installed, DO NOT rotate the camshafts or crankshaft without first locating the proper crankshaft position. Failure to do so will result in valve and/or piston damage. 2000 Dodge Intrepid V6-2.7L VIN R Fig. 74 4. Remove primary timing chain tensioner from right cylinder head (Fig. 74). 5. Remove camshaft position sensor from left cylinder head (Fig. 69).

2000 Dodge Intrepid Drive Belt: Service and Repair Removal and Installation

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Filed Under (Dodge) by admin on 19-09-2010

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AIR CONDITIONING BELT NOTE: The A/C drive belt self tensioner is NOT a dynamic tensioner. After tensioner adjustment bracket bolts are tightened, the torsion spring is no longer responsible for tensioning the A/C belt. The torsion spring is only used for initial belt tensioning only. REMOVAL 1. Remove generator/power steering belt. Fig. 42 2. Loosen BUT DO NOT REMOVE tensioner locking bolt and pivot bolt (Fig. 42). 3. Insert 1/2″ drive breaker bar into square opening on belt tensioner. Rotate tensioner counterclockwise until belt can be removed from pulleys (Fig. 42). 4. Slowly rotate tensioner clockwise to relieve spring load. INSTALLATION-NEW BELT WARNING: DO NOT REMOVE A/C BELT TENSIONER LOCKING BOLT WITHOUT FIRST HOLDING THE TENSIONER WITH A 1/2″ DRIVE BREAKER BAR, AS PERSONAL INJURY COULD RESULT. Fig. 43 NOTE: Verify that torsion spring position is in the new belt position before installing a NEW belt (Fig. 43). If torsion spring is not in the new belt position, follow steps 1 – 7 to change the tensioner spring from the USED belt position to the NEW belt position. 1. Insert a 1/2″ drive breaker bar into the square opening on the tensioner. Hold counterclockwise pressure on tensioner while removing the locking bolt (Fig. 42). 2. Carefully release spring load of the torsion spring on the tensioner. 3. Remove pivot bolt, tensioner, and spring from front timing cover. 4. Insert spring arm into the NEW belt position on the tensioner (Fig. 43). 5. Install torsion spring, tensioner, and pivot bolt. 6. Install pivot bolt. Tighten only finger tight, at this time. 7. Using a 1/2″ drive breaker bar, apply counterclockwise pressure until locking bolt can be installed.

2004 Dodge Intrepid CYLINDER HEAD COVER(S) REMOVAL

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Filed Under (Dodge) by admin on 15-09-2010

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NOTE: This procedure applies to either the left or right cylinder head cover. 1. 2. 3. 4. 5. 6. 7. Disconnect negative battery cable. Remove upper intake manifold. Disconnect electrical connectors from ignition coils and capacitor. Reposition electrical harness. Remove ground strap from right cylinder head. Disconnect electrical and vacuum harness retaining clips from cylinder head cover studs. Remove fasteners attaching ignition coil capacitors. Remove ignition coils. 8. Loosen all cylinder head cover fasteners (Fig. 27). NOTE: Cylinder head cover attaching bolts are captured to the cover. CAUTION: Make certain the double ended studs in the center of the cylinder head cover are loose before attempting to remove cover (Fig. 27). 9. Remove cylinder head cover(s). INSTALLATION