ADJUSTMENT - 2.7L ACCESSORY DRIVE BELTS
NOTE: A belt is considered “used” after 15 minutes of run time.

AIR CONDITIONING COMPRESSOR/GENERATOR BELT TENSIONING
WARNING: DO NOT EXERT MORE THAN 190 N·m (140 ft. lbs.) OF FORCE ON AIR CONDITIONING COMPRESSOR/GENERATOR BELT TENSIONER BRACKET DURING TENSIONING PROCEDURE.

NOTE: Ensure lower tensioner bracket bolt is finger tight/seated to prevent bending.

NEW BELT
Engage a torque wrench, with a maximum 2 inch extension in the 1/2 inch square opening of the tensioner bracket (Air Conditioning Compressor/Generator Belt Adjustment - 2.7L).
Apply 141 N·m (104 ft. lbs.) of torque, counter-clockwise to the tensioner bracket while tightening the upper fastener. Torque fastener to 28 N·m (250 in. lbs.) (Air Conditioning Compressor/Generator Belt Adjustment - 2.7L).
Remove torque wrench from tensioner bracket, and torque lower tensioner bracket fastener to 28 N·m (250 in. lbs.).
Verify proper belt tension.
USED BELT
Engage a torque wrench, with a maximum 2 inch extension in the 1/2 inch square opening of the tensioner bracket (Air Conditioning Compressor/Generator Belt Adjustment - 2.7L).
Apply 96 N·m (71 ft. lbs.) of torque, counter-clockwise to the tensioner bracket while tightening the upper fastener. Torque fastener to 28 N·m (250 in. lbs.) (Air Conditioning Compressor/Generator Belt Adjustment - 2.7L).
Remove torque wrench from tensioner bracket, and torque lower tensioner bracket fastener to 28 N·m (250 in. lbs.).
Verify proper belt tension.
POWER STEERING PUMP BELT TENSIONING
Insert a 1/2” drive breaker bar into the square opening on the power steering pump bracket.
Hold clockwise pressure on power steering pump bracket and tighten adjusting bolt.
Verify proper belt tension.

 

Symptom List:
P0132-1/1 O2 SENSOR SHORTED TO VOLTAGE
P0138-1/2 O2 SENSOR SHORTED TO VOLTAGE
P0152-2/1 O2 SENSOR SHORTED TO VOLTAGE
P0158-2/2 O2 SENSOR SHORTED TO VOLTAGE
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0132-1/1 O2 SENSOR SHORTED
TO VOLTAGE.
When Monitored and Set Condition:
P0132-1/1 O2 SENSOR SHORTED TO VOLTAGE
When Monitored: Engine running for 119 seconds. Battery voltage greater than 10 volts.
Coolant temperature above 80°C (176°F).
Set Condition: The Oxygen Sensor voltage is above 1.29 volts for 30 seconds. One trip
fault.
P0138-1/2 O2 SENSOR SHORTED TO VOLTAGE
When Monitored: The engine running for 119 seconds. Battery voltage greater than 10
volts. Coolant temperature above 80°C (176°F).
Set Condition: The Oxygen Sensor voltage is above 1.29 volts for 30 seconds. Two trip
fault.
P0152-2/1 O2 SENSOR SHORTED TO VOLTAGE
When Monitored: Battery voltage greater than 10 volts. Engine running for greater than
121 seconds. Coolant temperature above 80°C (176°F).
Set Condition: The Oxygen Sensor voltage is above 1.21 volts.
P0158-2/2 O2 SENSOR SHORTED TO VOLTAGE
When Monitored: With battery voltage greater than 10 volts. Engine running for more
than 2 minutes. Coolant temperature above 80°C (176°F).
Set Condition: The Oxygen Sensor voltage is above 1.21 volts.
POSSIBLE CAUSES
O2 SENSOR BELOW 1.2 VOLTS
O2 SENSOR OPERATION
O2 SENSOR SIGNAL SHORTED TO VOLTAGE
O2 SENSOR SIGNAL OPEN
O2 SENSOR GROUND CIRCUIT OPEN
PCM

 

PARKING BRAKE ADJUSTMENT
This vehicle uses a bent nail type park brake cable tension equalizer Bent Nail Park Brake Cable Tension Equalizer The bent nail tension equalizer it to be used only one time to set the park brake cable tension. If the park brake cables require adjustment during the life of the vehicle, a NEW tension equalizer MUST be installed before doing the park cable adjustment procedure.

Remove screws attaching rear of center console assembly to console bracket Attaching Screws At Rear Of Center Console
NOTE: For access to the 2 screws attaching the front of the center console to the forward console, the shifter boot or PRNDL plate must be removed from the center console. Refer to Body Components Section in Group 23 Body of this service manual.

Remove the 2 screws attaching the front of the center console to the forward console Attaching Screws At Front Of Center Console
Raise park brake hand lever assembly as high as it will go for required clearance to remove center console.
Remove center console assembly from vehicle.
Lower park brake lever handle.
Loosen adjusting nut Park Brake Lever Output Cable Adjustment Nut on park brake cable output cable. This will take tension off output cable, allowing it to be easily removed from tension equalizer.
CAUTION: Discard output cable retaining clip after removing it from park brake cable tension equalizer. Retainer is not to be re-used, a new retainer is to be installed when attaching output cable to tension equalizer.

Using a screwdriver Output Cable To Equalizer Retaining Clip unlatch the park brake output cable retainer. Then remove cable retainer from park brake cable tension equalizer.
Remove the park brake cable tension equalizer from the park brake lever output cable and the rear park brake cables Brake Cables And Tension Equalizer
CAUTION: A new cable tension equalizer must be installed when adjusting park brake cable tension.

Install a NEW park brake cable tension equalizer on the park brake lever output cable and rear park brake cables Brake Cables And Tension Equalizer
CAUTION: A new park brake lever output cable retainer must be used when installing output cable on cable tension equalizer. Cable retainer usage is required to ensure output cable can not separate from tension equalizer.

Install a new park brake lever output cable to tension equalizer retaining clip Cable Retainer Installed On Tension Equalizer on tension equalizer. The cable retainer Cable Retainer Installed On Tension Equalizer must be closed and securely latched.
Cable tension, for the parking brake system is to be correctly adjusted using the following steps.
Position park brake lever so it is in the fully released position.
Tighten adjusting nut Park Brake Lever Output Cable Adjustment on park brake lever output cable Park Brake Lever Output Cable Adjustment until 12mm millimeters of thread is out past top edge of adjustment nut Park Brake Lever Output Cable Adjustment
Actuate the park brake lever to its fully applied position (15 clicks) 1 time and then release.
NOTE: Actuating the park brake lever to its fully applied position 1 time after tightening the adjustment nut will yield (stretch) the bent nail portion of the tension equalizer approximately 1/4 inch. This process will correctly set the park brake cable tension.

Check the rear wheels of the vehicle, they should rotate freely without dragging.
After the park brake cable tension has been properly adjusted, check for free play in park brake lever. Park brake hand lever should feel firm at all clicks, with a maximum of 15 clicks of lever travel possible.
Install the center console back in the vehicle.
Install the 2 screws attaching the front of the center console to the forward console Attaching Screws At Front Of Center Console
Install screws attaching rear of center console assembly to console bracket Attaching Screws At Rear Of Center Console
Install shifter boot or PRNDL plate back in the center console.

 

BLOWER MOTOR AND WHEEL ASSEMBLY
The blower motor is located on the right side of the heater housing.

REMOVAL
Disconnect battery.
Remove lower right under panel silencer duct.
Remove blower motor connector from resistor block Blower Motor Wiring
Remove blower motor case retaining screws.
Lower blower motor case from housing Blower Motor
Remove fan scroll from motor shaft.
Remove motor from motor case.
INSTALLATION
To install, reverse removal procedure.

 

TIMING BELT
CAUTION: The 2.5L engine is a Non-freewheeling design. When the timing belt is removed, 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.

REMOVAL
Remove timing belt covers. Refer to procedure in this section.
Mark timing belt running direction for installation Timing Belt System Mark Direction of Timing Belt
Loosen timing belt tensioner center bolt Timing Belt Engine Sprocket Timing and remove auto tensioner.
Remove timing belt
CAUTION: Coolant or oil leakage on timing belt will shorten its life drastically. If timing belt is seriously contaminated, it must be replaced. Clean all components and correct source of leak.

CAMSHAFT AND CRANKSHAFT TIMING PROCEDURE
TIMING BELT TENSIONER
When tensioner is removed from the engine it is necessary to compress the plunger into the tensioner body.
Place the tensioner into a vise and slowly compress the plunger Timing Belt Tensioner Compressing
CAUTION: Index the tensioner in the vise the same way it is installed on the engine. This is to ensure proper locking pin orientation when tensioner is installed on the engine.

When plunger is compressed into the tensioner body, install a locking pin through the body and plunger Timing Belt Tensioner Compressing
INSTALLATION
Set crankshaft sprocket to TDC by aligning the sprocket mark with the mark on the oil pump housing. Then rotate crankshaft 3 notches before TDC Crankshaft Sprocket Timing
Set camshaft sprockets to the aligning marks on the sprockets with the marks on the rear timing belt cover Camshaft Sprocket Timing
Install timing belt on right camshaft sprocket. Install a binder clip on the belt and sprocket so the belt will not slip out of position. Keeping the belt taught, install belt under the water pump pulley and then around the left camshaft sprocket. Install an additional binder clip on the left sprocket and belt.
Rotate the crankshaft to TDC Adjusting Crankshaft Sprocket for Timing Belt Continue routing the belt around the idler pulley, crankshaft sprocket, and tensioner pulley.
To tension belt perform the following:
Apply rotating force to the crankshaft sprocket in the clockwise direction, check that all timing marks are aligned.
Loosen tensioner pulley center bolt.
Using Special Tool MD 998767 and a torque wrench on the tensioner pulley. Apply 4.4 N·m (38.9 in. lbs.) of torque to tensioner Timing Belt Tension Adjustment Tighten tensioner pulley bolt to 48 N·m (35 ft. lbs.)
With torque being applied to the tensioner pulley, install the hydraulic tensioner to the tensioner pulley bracket. Tighten tensioner fasteners to 23 N·m (205 in. lbs.)
Pull tensioner plunger pin
Rotate crankshaft 2 revolutions in a clockwise direction ONLY and check the alignment of the timing marks Timing Belt Engine Sprocket Timing Install tensioner pin into assembly. The pin should slide in and out without any resistance. If the pin does not slide freely, perform the procedure again.
Install timing belt covers. Refer to procedure in this section.
Install right engine mount. Refer to procedure in this section.
Install crankshaft damper and crankshaft damper bolt. Tighten to 182 N·m (134 ft. lbs.)
Install accessory drive belts. Cooling System for the procedure.
Raise vehicle on hoist and install drive belt splash shield.

 

TIMING BELT - WITH HYDRAULIC TENSIONER 2.0 SOHC Engine
CHECKING BELT TIMING - COVER INSTALLED
Remove number one spark plug.
Using a dial indicator, set number one cylinder to TDC on the compression stroke.
Remove the access plug from the outer timing belt cover Timing Belt System
Check the timing mark on the camshaft sprocket, it should align with the arrow on the rear belt cover Camshaft Timing Marks
REMOVAL - TIMING BELT
Disconnect negative cable from auxiliary jumper terminal.
Remove accessory drive belts. Refer toCooling System for procedure.
Raise vehicle on a hoist and remove right inner splash shield Right Inner Splash Shield
Remove crankshaft damper bolt. Remove damper using the large side of Special Tool 1026 and insert 6827-A Crankshaft Damper - Removal
Lower vehicle and place a jack under engine.
Remove right engine mount. Refer to procedure in this section.
Remove generator and bracket Generator and Brackets Refer to Charging System for specific procedure.
Remove right engine mount bracket Right Engine Mount Bracket
Remove front timing belt cover Timing Belt Cover
CAUTION: Align camshaft and crankshaft timing marks before removing the timing belt.

Loosen timing belt tensioner fasteners Remove Timing Belt and remove timing belt and tensioner
CAUTION: Do not loosen, tighten, or remove the tensioner pivot bolt Tensioner Pulley Assembly

.
CAMSHAFT AND CRANKSHAFT TIMING PROCEDURE AND BELT INSTALLATION - SOHC ENGINE
When tensioner is removed from the engine it is necessary to compress the plunger into the tensioner body.
Place the tensioner into a vise equipped with soft jaws and slowly compress the plunger Compressing Timing Belt Tensioner
CAUTION: Index the tensioner in the vise the same way it is installed on the engine. This is to ensure proper pin orientation when tensioner is installed on the engine.

When plunger is compressed into the tensioner body install a 1.9 mm (5/64) Allen wrench or pin through the body and plunger to retain plunger in place until tensioner is installed
Set crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing, then back off to 3 notches before TDC Crankshaft Sprocket Timing
Set camshaft to TDC by aligning mark on sprocket with the arrow on the rear of timing belt cover Camshaft Timing Mark
Move crankshaft to 1/2 mark before TDC Adjusting Crankshaft Sprocket for Timing Belt Installation for belt installation
Install timing belt. Starting at the crankshaft, go around the water pump sprocket and then around the camshaft sprocket.
Move crankshaft sprocket to TDC to take up belt slack. Install tensioner to block but do not tighten fasteners.
Using a torque wrench on the tensioner pulley apply 28 N·m (250 in. lbs.) of torque Adjusting Timing Belt Tension
With torque being applied to the tensioner pulley move the tensioner up against the tensioner pulley bracket and tighten fasteners to 31 N·m (23 ft. lbs.) Adjusting Timing Belt Tension
Pull tensioner plunger pin. Pretension is correct when pin can be removed and installed.
Rotate crankshaft 2 revolutions and check the alignment of the timing marks Adjusting Timing Belt Tension
Install front half of timing cover.
Install engine mount bracket.
Install generator bracket to engine Generator and Brackets Tighten attaching bolts to 61 N·m (45 ft. lbs.)
Install generator Generator and Brackets Refer to Charging System for procedure.
Install right engine mount. Refer to procedure in this section.
Remove jack from under engine.
Install crankshaft damper using M12-1.75 x 150 mm bolt, washer, thrust bearing and nut from Special Tool 6792. Install crankshaft damper bolt and tighten to 142 N·m (105 ft. lbs.) Crankshaft Damper - Installation
Install accessory drive belts. Refer toCooling System Accessory Drive section for procedure.
Raise vehicle on hoist and install right inner splash shield.
Lower vehicle and connect negative cable

 

This is a DIY section, Not a Tech section. If you have a problem or a Tech question. Plaese post on the open forum. Thats because you will get an answer sooner. If you haven't gotten an answer after a few days, send me a pm. Also let me know if there are any other remove and install information you need. Thank you all dodge forum members.

 

I'd like to know a relatively easy way to adjust the steering wheel on my '02 Stratus (2.7L four-door). Despite having it aligned several times, the wheel is off (clockwise) just enough to irritate me. I know it involves adjusting the tie rods after loosening the lock nut, and doing it the same amount: shortening one and lengthening the other...in my case, passenger side rotated to the rear of the car, driver's side to the front. I tried the other day but was unable to get the adjuster to budge. Do the wheels have to be off the ground? Many thanks.

 

Am trying to replace the shifter cable but cannot remove the bolts behind the heater core. Can anyone help? Is there a special tool needed to remove it? This is a 2002 standard coupe RT.

 

only the 2.4L has valve/piston clearance. good news if timing belt fails.