Caravan, Town & Country 2006-2007

Timing Belt & Sprockets

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Removal & Installation



2.4L Engine

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

  1. Remove or disconnect the following:
    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.



    Negative battery cable
     
    Right front wheel and inner splash shield
     
    Accessory drive belts
     
    Crankshaft damper
     
    A/C compressor/alternator tensioner and pulley assembly
     
    Lower front timing cover
     
    Upper front timing cover
     
    Right engine mount
     
    Engine mount bracket
     

  2.  
  3. Rotate the crankshaft until the Top Dead Center (TDC) mark on the oil pump housing aligns with the TDC mark on the camshaft sprocket (located on the trailing edge of the tooth).
  4.  
  5. Loosen the timing belt tensioner lock bolt.
  6.  
  7. Insert a 6mm Allen wrench into the hexagon opening located on the top plate of the belt tensioner pulley. Rotate the top plate clockwise until there is enough slack to remove the belt.
  8.  
  9. If necessary, remove the camshaft timing belt sprockets.
  10.  
  11. If necessary, remove the crankshaft timing belt sprocket using removal tool No. 6793, or equivalent.
  12.  
  13. Place the tensioner into a soft-jawed vise to compress the tensioner.
  14.  
  15. 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. Camshaft and crankshaft alignment marks-2.4L 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-2.4L engine



    Click image to see an enlarged view

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

  16.  

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 timing marks so the exhaust camshaft is 1 / 2 notch below intake camshaft sprocket. Make sure the arrows on both camshaft sprockets are facing up
  8.  
  9. Install the timing belt starting at the crankshaft, then around the water pump sprocket, idler pulley, camshaft sprockets and around the tensioner pulley.
  10.  
  11. Move the exhaust camshaft sprocket counterclockwise to take up the belt slack.
  12.  
  13. Insert a 6mm Allen wrench into the hexagon opening located on the top plate of the belt tensioner pulley. Rotate the top plate counterclockwise until there is no slack on the belt. The tensioner setting notch will start to move clockwise. Watch the notch and continue rotating the top plate counterclockwise until the setting notch is aligned with the spring tang. Using the Allen wrench to prevent the top plate from moving, tighten the tensioner lock bolt to 220 inch lbs. (25 Nm). The setting notch and spring tang should remain aligned after the lock nut is tightened.
  14.  
  15. Rotate the crankshaft 2 revolutions and recheck the timing marks.
  16.  
  17. Check the spring tang is within the tolerance window. If not within the window, reinsert the Allen wrench and into the hexagon opening located on the top plate of the belt tensioner pulley. Rotate the top plate counterclockwise until there is no slack on the belt. The tensioner setting notch will start to move clockwise. Watch the notch and continue rotating the top plate counterclockwise until the setting notch is aligned with the spring tang. Using the Allen wrench to prevent the top plate from moving, tighten the tensioner lock bolt to 220 inch lbs. (25 Nm). The setting notch and spring tang should remain aligned after the lock nut is tightened.
  18.  
  19. Install the engine mount bracket.
  20.  
  21. Install the front timing belt covers.
  22.  
  23. Install the A/C compressor/alternator tensioner and pulley assembly.
  24.  
  25. Install the right engine mount.
  26.  
  27. Install the crankshaft damper
  28.  
  29. Install the accessory drive belts and adjust to the proper tension.
  30.  
  31. Install the right inner splash shield and wheel.
  32.  
  33. Reconnect the negative battery cable.
  34.  
  35. Perform the crankshaft and camshaft relearn alignment procedure using the DRB scan tool, or equivalent.
  36.  

3.0L 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-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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