Chrysler Caravan/Voyager/Town and Country 1996-1999

Timing Belt and Sprockets

Print

REMOVAL & INSTALLATION



2.4L Engine

See Figures 1, 2, 3 and 4



Click image to see an enlarged view

Fig. Fig. 1: Camshaft and crankshaft timing marks for 2.4L engine



Click image to see an enlarged view

Fig. Fig. 2: To lock the timing belt tensioner, be sure to fully insert the smaller Allen wrench into the tensioner as shown- 2.4L engine

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

  1. Disconnect the negative battery cable.
  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.
  16.  

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.

  1. 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.
  2.  
  3. Remove the timing belt and the tensioner.
  4.  
  5. If necessary, remove the camshaft timing belt sprockets.
  6.  
  7. If necessary, remove the crankshaft timing belt sprocket using removal tool No. 6793 or equivalent.
  8.  
  9. Place the tensioner into a soft-jawed vise to compress the tensioner.
  10.  
  11. After compressing the tensioner, insert a pin ( 5 / 64 in. Allen wrench will also work) into the plunger side hole to retain the plunger until installation.
  12.  



Click image to see an enlarged view

Fig. Fig. 3: Timing belt installation detail-2.4L engine (notice the camshaft alignment)



Click image to see an enlarged view

Fig. Fig. 4: The upper sprockets should be held in place with the special tool for removal and installation

To install:
  1. If necessary, using 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.
  22.  


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.

  1. Rotate the crankshaft two revolutions and recheck the timing marks. Wait several minutes and then recheck that the plunger pin can easily be removed and installed.
  2.  
  3. Install the front timing belt cover.
  4.  
  5. Install the engine mount bracket.
  6.  
  7. Install the right engine mount.
  8.  
  9. Remove the floor jack from under the vehicle.
  10.  
  11. Install the crankshaft damper and tighten it to 105 ft. lbs. (142 Nm).
  12.  
  13. Install the accessory drive belts and adjust to the proper tension.
  14.  
  15. Install the right inner splash shield.
  16.  
  17. Reconnect the negative battery cable.
  18.  
  19. Perform the crankshaft and camshaft relearn alignment procedure using the DRB scan tool or equivalent.
  20.  

3.0L Engine

See Figures 5, 6, 7, 8, 9, 10, 11, 12 and 13



Click image to see an enlarged view

Fig. Fig. 5: Exploded view of the timing belt and sprocket assembly-3.0L engine



Click image to see an enlarged view

Fig. Fig. 6: Mark the direction of travel for the timing belt for correct installation



Click image to see an enlarged view

Fig. Fig. 7: Turn the center tensioner pulley bolt until the timing belt has enough slack ...



Click image to see an enlarged view

Fig. Fig. 8: ... then slide the timing belt off of the camshaft sprockets

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.
  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.
  16.  

If the original belt is being reused, be sure to install it in the same rotational direction.

  1. 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.
  2.  


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.



Click image to see an enlarged view

Fig. Fig. 9: Rent or borrow the special tool to hold the camshaft sprockets steady ...



Click image to see an enlarged view

Fig. Fig. 10: ... while loosening the center retaining bolt on the camshaft pulley, then ...



Click image to see an enlarged view

Fig. Fig. 11: ... remove the camshaft sprocket from the end of the camshaft



Click image to see an enlarged view

Fig. Fig. 12: Timing belt tensioner and spring positions



Click image to see an enlarged view

Fig. Fig. 13: Timing belt routing and timing mark locations

  1. 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.
  2.  
  3. Install the crankshaft sprocket flange.
  4.  
  5. Loosen the tensioner bolt and allow the tensioner spring to tension the belt.
  6.  
  7. Rotate the crankshaft two full turns in a clockwise direction. Turn the crankshaft smoothly and in a clockwise direction only.
  8.  
  9. Again line up the timing marks. If all marks are aligned, tighten the tensioner bolt to 250 inch lbs. (28 Nm). Otherwise repeat the installation procedure.
  10.  
  11. Install the timing belt covers. Install the engine support bracket. Tighten the support bracket mounting bolts to 35 ft. lbs. (47 Nm).
  12.  
  13. Install the engine mount insulator, torsional damper and crankshaft pulleys. Tighten the crankshaft pulley bolt to 112 ft. lbs. (151 Nm).
  14.  
  15. Install the accessory drive belts and adjust them to the proper tension.
  16.  
  17. Reconnect the negative battery cable.
  18.  
  19. Run the engine and check for proper operation. Road test the vehicle.
  20.  

inspection

See Figures 14, 15, 16, 17 and 18


WARNING
Timing belt maintenance is extremely important! All Neon models utilize an interference-type, non-free-wheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. The recommended replacement interval for the timing belt is 102,000 miles (163,000km), or sooner.

You would be wise to check the belt periodically to make sure it has not become damaged or worn. Generally speaking, a severely worn belt may cause engine performance to drop dramatically, but a damaged belt (which could give out suddenly) may not give as much warning. In general, any time the engine timing cover(s) is(are) removed you should inspect the belt for premature parting, severe cracks or missing teeth. Also, an access plug or cover is provided in the upper portion of the timing cover so that camshaft timing can be checked without cover removal. If timing is found to be off, cover removal and further belt inspection or replacement is necessary.



Click image to see an enlarged view

Fig. Fig. 14: Check for premature parting of the belt



Click image to see an enlarged view

Fig. Fig. 15: Check if the teeth are cracked or damaged



Click image to see an enlarged view

Fig. Fig. 16: Look for noticeable cracks or wear on the belt face



Click image to see an enlarged view

Fig. Fig. 17: You may only have damage on one side of the belt; if so, the guide could be the culprit



Click image to see an enlarged view

Fig. Fig. 18: Foreign materials can get in between the teeth and cause damage

 
label.common.footer.alt.autozoneLogo