Caravan, Grand Voyager, Town and Country, Voyager, 2000-2004

Timing Belt

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Removal & Installation




NOTE
The Chrysler Town & Country is available only with a 3.3L or 3.8L engine, both of which are equipped with timing chains.

2.4L (VIN B) Engine

NOTE
You may need DRB scan tool to perform the crankshaft and camshaft relearn alignment procedure.

  1. Disconnect the negative battery cable remote connector, located on the left strut tower.
  2.  
  3. Remove the right inner splash shield.
  4.  
  5. Remove the accessory drive belts.
  6.  
  7. Remove the crankshaft damper.
  8.  
  9. Remove the right engine mount.
  10.  
  11. Place a floor jack under the engine to support it while the engine mount is removed.
  12.  
  13. Remove the engine mount bracket.
  14.  
  15. Remove the timing belt cover.
    NOTE
    This is an interference engine. Do not rotate the crankshaft or the camshafts after the timing belt has been removed. Damage to the valve components may occur. Before removing the timing belt, always align the timing marks.

  16.  
  17. Align the timing marks of the timing belt sprockets to the timing marks on the rear timing belt cover and oil pump cover. Loosen the timing belt tensioner bolts.
  18.  
  19. Remove the timing belt and the tensioner.
  20.  
  21. If necessary, remove the camshaft timing belt sprockets.
  22.  
  23. If necessary, remove the crankshaft timing belt sprocket using removal tool No. 6793, or equivalent.
  24.  
  25. Place the tensioner into a soft-jawed vise to compress the tensioner.
  26.  
  27. After compressing the tensioner, insert a pin (a 5 / 64 in. Allen wrench will also work) into the plunger side hole to retain the plunger until installation.

    Click image to see an enlarged view

    Fig. Timing cover and engine mounting bracket bolt locations-Chrysler 2.4L (VIN B) engine



    Click image to see an enlarged view

    Fig. Camshaft and crankshaft alignment marks-Chrysler 2.4L (VIN B) engine



    Click image to see an enlarged view

    Fig. To lock the timing belt tensioner, be sure to fully insert the smaller Allen wrench into the tensioner as shown-Chrysler 2.4L (VIN B) engine



    Click image to see an enlarged view

    Fig. Installation of the timing belt, notice the camshaft alignment-Chrysler 2.4L (VIN B) engine

  28.  

To install:

  1. If necessary, use tool No. 6792, or equivalent, to install the crankshaft timing belt sprocket onto the crankshaft.
  2.  
  3. If necessary, install the camshaft sprockets onto the camshafts. Install and tighten the camshaft sprocket bolts to 75 ft. lbs. (101 Nm).
  4.  
  5. Set the crankshaft sprocket to Top Dead Center (TDC) by aligning the notch on the sprocket with the arrow on the oil pump housing.
  6.  
  7. Set the camshafts to align the timing marks on the sprockets.
  8.  
  9. Move the crankshaft to 1 / 2 notch before TDC.
  10.  
  11. Install the timing belt starting at the crankshaft, then around the water pump sprocket, idler pulley, camshaft sprockets and around the tensioner pulley.
  12.  
  13. Move the crankshaft sprocket to TDC to take up the belt slack.
  14.  
  15. Install the tensioner on the engine block but do not tighten.
  16.  
  17. Using a torque wrench on the tensioner pulley, apply 250 inch lbs. (28 Nm) of torque to the tensioner pulley.
  18.  
  19. With torque being applied to the tensioner pulley, move the tensioner up against the tensioner pulley bracket and tighten the fasteners to 23 ft. lbs. (31 Nm).
  20.  
  21. Remove the tensioner plunger pin, the tension is correct when the plunger pin can be removed and reinserted easily.
    WARNING
    If any binding is felt when adjusting the timing belt tension by turning the crankshaft, STOP turning the engine, because the pistons may be hitting the valves.

  22.  
  23. Rotate the crankshaft 2 revolutions and recheck the timing marks. Wait several minutes and then recheck that the plunger pin can easily be removed and installed.
  24.  
  25. Install the front timing belt cover.
  26.  
  27. Install the engine mount bracket.
  28.  
  29. Install the right engine mount.
  30.  
  31. Remove the floor jack from under the vehicle.
  32.  
  33. Install the crankshaft damper and tighten it to 105 ft. lbs. (142 Nm).
  34.  
  35. Install the accessory drive belts and adjust to the proper tension.
  36.  
  37. Install the right inner splash shield.
  38.  
  39. Reconnect the negative battery cable.
  40.  
  41. Perform the crankshaft and camshaft relearn alignment procedure using the DRB scan tool, or equivalent.
  42.  

3.0L (VIN 3) Engine

The timing belt can be inspected by removing the upper front outer timing belt cover.

Working on any engine (especially overhead camshaft engines) requires much care be given to valve timing. It is good practice to set the engine up at TDC No. 1 cylinder firing position before beginning work. Verify that all timing marks on the crankshaft and camshaft sprockets are properly aligned before removing the timing belt and starting camshaft service. This serves as a point of reference for all work that follows. Valve timing is very important and engine damage will result if the work is incorrect.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the accessory drive belts. Remove the engine mount insulator from the engine support bracket.
  4.  
  5. Remove the engine support bracket. Remove the crankshaft pulleys and torsional damper. Remove the timing belt covers.
  6.  
  7. Rotate the crankshaft until the sprocket timing marks are aligned. The crankshaft sprocket timing mark should align with the oil pump timing mark. The rear camshaft sprocket timing mark should align with the generator bracket timing mark and the front camshaft sprocket timing mark should align with the inner timing belt cover timing mark.
  8.  
  9. If the belt is to be reused, mark the direction of rotation on the belt for installation reference.
  10.  
  11. Loosen the timing belt tensioner bolt and remove the timing belt.
  12.  
  13. If necessary, remove the timing belt tensioner.
  14.  
  15. Remove the crankshaft sprocket flange shield and crankshaft sprocket.
  16.  
  17. Hold the camshaft sprocket using spanner tool MB990775, or equivalent, and remove the camshaft sprocket bolt and washer. Remove the camshaft sprocket.

    Click image to see an enlarged view

    Fig. Timing belt sprocket timing marks for proper timing belt installation-Chrysler 3.0L (VIN 3) engine

  18.  

To install:

  1. Install the camshaft sprocket on the camshaft with the retaining bolt and washer. Hold the camshaft sprocket using spanner tool MB990775, or equivalent, and tighten the bolt to 70 ft. lbs. (95 Nm).
  2.  
  3. Install the crankshaft sprocket.
  4.  
  5. If removed, install the timing belt tensioner and tensioner spring. Hook the spring upper end to the water pump pin and the lower end to the tensioner bracket with the hook out.
  6.  
  7. Turn the timing belt tensioner counterclockwise full travel in the adjustment slot and tighten the bolt to temporarily hold it in this position.
  8.  
  9. Rotate the crankshaft sprocket until its timing mark is aligned with the oil pump timing mark.
  10.  
  11. Rotate the rear camshaft sprocket until its timing mark is aligned with the timing mark on the generator bracket.
  12.  
  13. Rotate the front (radiator side) camshaft sprocket until its mark is aligned with the timing mark on the inner timing belt cover.
  14.  
  15. Install the timing belt on the crankshaft sprocket while keeping the belt tight on the tension side.
    NOTE
    If the original belt is being reused, be sure to install it in the same rotational direction.

  16.  
  17. Position the timing belt over the front camshaft sprocket (radiator side). Next, position the belt under the water pump pulley, then over the rear camshaft sprocket and finally over the tensioner.
    WARNING
    If any binding is felt when adjusting the timing belt tension by turning the crankshaft, STOP turning the engine, because the pistons may be hitting the valves.

  18.  
  19. Apply rotating force in the opposite direction to the front camshaft sprocket (radiator side) to create tension on the timing belt tension side. Check that all timing marks are aligned.
  20.  
  21. Install the crankshaft sprocket flange.
  22.  
  23. Loosen the tensioner bolt and allow the tensioner spring to tension the belt.
  24.  
  25. Rotate the crankshaft 2 full turns in a clockwise direction. Turn the crankshaft smoothly and in a clockwise direction only.
  26.  
  27. Align the timing marks. If all marks are aligned, tighten the tensioner bolt to 250 inch lbs. (28 Nm). Otherwise repeat the installation procedure.
  28.  
  29. Install the timing belt covers. Install the engine support bracket. Tighten the support bracket mounting bolts to 35 ft. lbs. (47 Nm).
  30.  
  31. Install the engine mount insulator, torsional damper and crankshaft pulleys. Tighten the crankshaft pulley bolt to 112 ft. lbs. (151 Nm).
  32.  
  33. Install the accessory drive belts and adjust them to the proper tension.
  34.  
  35. Reconnect the negative battery cable.
  36.  
  37. Run the engine and check for proper operation. Road test the vehicle.
  38.  

 
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