Chrysler Caravan/Voyager/Town n Country 1984-1995

Timing Belt/Chain

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REMOVAL & INSTALLATION



2.2L and 2.5L Engines

See Figures 1, 2, 3, 4 and 5



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Fig. Fig. 1: Loosening the timing belt tensioner screw



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Fig. Fig. 2: Loosen the belt tensioner screw, then rotate the hex nut to release the tension. During installation, rotate this hex nut to increase belt tension, then tighten the screw



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Fig. Fig. 3: Timing belt inspection



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Fig. Fig. 4: Crankshaft and intermediate shaft timing mark alignment-2.2L and 2.5L engines



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Fig. Fig. 5: Camshaft sprocket timing alignment-2.2L and 2.5L engines

  1. Remove the solid mount compressor bracket. For more details, refer to the solid mount compressor bracket procedure outlined earlier in this section.
  2.  
  3. Remove the accessory drive belts.
  4.  
  5. Remove the timing belt cover. For more information, refer to the timing belt cover procedures earlier in this section.
  6.  
  7. Place a hydraulic floor jack under the engine.
  8.  
  9. Separate the right engine mount and raise the engine slightly.
  10.  
  11. Loosen the timing belt tensioner screw, rotate the hex nut, and remove timing belt.
  12.  

To install:
  1. Turn the crankshaft and intermediate shaft until markings on both sprockets are aligned.
  2.  
  3. Rotate the camshaft so that the arrows on the hub are in line with No. 1 camshaft cap to cylinder head line. Small hole must be in vertical center line.
  4.  
  5. Install the timing belt over the drive sprockets and adjust.
  6.  
  7. Tighten the tensioner by turning the tensioner hex to the right. Tension should be correct when the belt can be twisted 90° with the thumb and forefinger, midway between the camshaft and intermediate sprocket.
  8.  
  9. Turn the engine clockwise from TDC 2 revolutions with crankshaft bolt. Check the timing marks for correct alignment.
  10.  


WARNING
Do not use the camshaft or intermediate shaft to rotate the engine. Also, do not allow oil or solvent to contact the timing belt, as they will deteriorate the belt and cause slipping.

  1. Tighten locknut on tensioner while holding weighted wrench in position to 45 ft. lbs. (61 Nm).
  2.  
  3. Install the timing belt cover.
  4.  
  5. Install the accessory drive belts.
  6.  

With timing belt cover installed and number one cylinder at TDC, the small hole in the cam sprocket should be centered in timing belt cover hole.

2.6L Engines

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



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Fig. Fig. 6: Mark the chain and sprockets and remove the bolt, washer distributor drive gear and sprocket-2.6L engines



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Fig. Fig. 7: Timing chain components-2.6L engines



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Fig. Fig. 8: Timing chain installation-2.6L engines



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Fig. Fig. 9: Timing/silent shaft chain and drive components-2.6L engines



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Fig. Fig. 10: Dowel pin set at 12 o'clock-2.6L engines



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Fig. Fig. 11: Oil pump and silent shaft shaft installation-2.6L engines



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Fig. Fig. 12: Timing mark alignment for the silent shaft timing chain installation-2.6L engines

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the accessory drive belts.
  4.  
  5. Remove the timing chain case cover. For more information, refer to the Front Timing Cover and Seal procedure, earlier in this section.
  6.  
  7. Remove the bolts securing the silent shaft chain guides. Mark all parts for proper location during assembly.
  8.  
  9. Remove the sprocket bolts, silent shaft drive chain, crankshaft/silent sprocket, silent shaft sprockets and spacer.
  10.  
  11. Remove the camshaft sprocket bolt and washer.
  12.  
  13. Remove the distributor drive gear.
  14.  
  15. Remove the camshaft sprocket holder and timing chain guides.
  16.  
  17. Depress the tensioner and remove the timing chain and camshaft sprocket.
  18.  
  19. Remove the crankshaft sprocket.
  20.  
  21. Remove the tensioner shoe, washer and spring.
  22.  

To install:
  1. Clean and inspect all parts.
  2.  
  3. Check the tensioner shoe for wear or damage and tensioner spring for deterioration. The spring free-length should be 2.59 in. (65.7mm).
  4.  
  5. Check the chain cover for damage or cracks.
  6.  
  7. Check the silent shaft and camshaft chain guides for damage or excessive wear.
  8.  
  9. Check the silent shaft sprocket cushion ring for free and smooth rotation and ring guides for damage.
  10.  
  11. Check the silent chain and timing chain for excessive play, wear or damage links.
  12.  
  13. Check all sprockets for wear or damage teeth.
  14.  
  15. Rotate the camshaft until the dowel pin is at vertical center line with cylinder.
  16.  
  17. Install the timing chain sprocket holders.
  18.  
  19. Rotate the crankshaft until No. 1 piston is at Top Dead Center (TDC) of its compression stroke.
  20.  
  21. Install the timing chain tensioner spring, washer and shoe on oil pump body.
  22.  
  23. Assemble the timing chain on the camshaft and crankshaft sprockets.
  24.  

The mating mark on the camshaft and crankshaft sprocket teeth must line up with plated links on timing chain.

  1. While holding the sprockets and chain as an assembly, install the crankshaft sprocket to key way of crankshaft and camshaft sprocket to dowel pin of camshaft.
  2.  
  3. Install the distributor drive gear, camshaft sprocket bolt and washer, and tighten bolt to 40 ft. lbs. (54 Nm).
  4.  
  5. Install the silent shaft chain drive sprocket on crankshaft.
  6.  
  7. Assemble the silent shaft chain to oil pump sprocket and to silent shaft sprocket.
  8.  

The timing marks on the sprockets teeth must line up with plated links on of silent shaft chain.

  1. While holding the parts as an assembly, align the crankshaft sprocket plated link with the punch mark on the sprocket. With the chain installed on crankshaft sprocket, install the oil pump sprocket and silent chain sprocket on their respective shafts.
  2.  
  3. Install the oil pump and silent shaft sprocket bolts and tighten to 25 ft. lbs. (34 Nm).
  4.  
  5. Loosely install the 3 silent shaft chain guides and adjust silent shaft chain tension as follows.
    1. Tighten chain guide A mounting screws.
    2.  
    3. Tighten chain guide C mounting screws.
    4.  
    5. Slightly rotate the oil pump and silent shaft sprockets to remove any slack in the silent shaft chain.
    6.  
    7. Adjust the position of chain guide B so that when the chain is pulled inward, the clearance between chain guide B and the chain links will be 0.039-0.138 in. (1.0-3.5mm). Tighten chain guide B mounting screws.
    8.  

  6.  
  7. Install a new timing case cover gasket and install the timing case cover.
  8.  

SILENT SHAFT CHAIN ADJUSTMENT

See Figure 13



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Fig. Fig. 13: Silent shaft adjustment-2.6L engines

If necessary, the silent shaft chain adjustment may be performed without removing the timing chain case cover. Proceed as follows:

  1. Remove the access cover from the timing case cover.
  2.  
  3. Through the access hole loosen special bolt B .
  4.  
  5. Using your finger only, push on the boss to apply tension.
  6.  
  7. While applying tension, tighten special bolt B to 13 ft. lbs. (18 Nm).
  8.  
  9. Install the access cover to the timing chain case cover.
  10.  

3.0L Engines

See Figures 14, 15, 16 and 17



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Fig. Fig. 14: Sprocket timing for belt installation-3.0L engines



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Fig. Fig. 15: Secure the sprocket when removing or installing the nut-3.0L engines



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Fig. Fig. 16: Timing belt tensioner-3.0L engines



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Fig. Fig. 17: Positioning the tensioner-3.0L engines

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

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the accessory drive belts.
  4.  
  5. Remove the timing belt covers.
  6.  
  7. Identify the timing belt running direction to avoid reversal during installation.
  8.  
  9. Loosen timing belt tensioner bolt and remove timing belt.
  10.  
  11. Remove the crankshaft sprocket flange.
  12.  

To install:
  1. Rotate the crankshaft sprocket until timing mark on crankshaft sprocket is lined up with the oil pump timing mark at 1 o'clock position.
  2.  
  3. Rotate the (inner) camshaft sprocket until mark on (inner) camshaft sprocket is lined up with the timing mark on alternator bracket.
  4.  
  5. Rotate the (outer) camshaft sprocket (radiator side) until mark on the sprocket is lined up with the timing mark on the timing belt inner cover. Refer to timing belt illustration.
  6.  
  7. Install the timing belt on the crankshaft sprocket while maintaining pressure on the tensioner side.
  8.  
  9. Position the timing belt over the camshaft sprocket (radiator side). Next, position the belt under the water pump pulley, then over the (inner) sprocket and finally over the tensioner.
  10.  
  11. Apply rotating force in the opposite direction to the camshaft sprocket (radiator side) to create tension on the timing belt tension side.
  12.  
  13. Rotate the crankshaft in a clockwise direction and recheck engine timing marks.
  14.  
  15. Install the crankshaft sprocket flange.
  16.  
  17. Loosen the tensioner bolt and allow tensioner spring to tension the belt.
  18.  
  19. Again rotate the crankshaft in a clockwise direction (2) full turns. Recheck the engine timing. Tighten the tensioner bolt to 23 ft. lbs. (31 Nm).
  20.  
  21. Install the timing covers.
  22.  
  23. Install the accessory drive belts.
  24.  
  25. Connect battery negative cable.
  26.  

3.3L and 3.8L Engines

See Figure 18



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Fig. Fig. 18: Timing mark alignment-3.3L and 3.8L engines

  1. If possible, position the engine so that the No. 1 piston is at TDC on the compression stroke. Disconnect the negative battery cable. Drain the coolant.
  2.  
  3. Remove the timing chain case cover. For more information, refer to the Front Timing Cover and Seal procedure, earlier in this section.
  4.  
  5. Remove the camshaft gear attaching cup washer and remove the timing chain with both gears attached. Remove the timing chain snubber.
  6.  

To install:
  1. Assemble the timing chain and gears.
  2.  
  3. Turn the crankshaft and camshaft to line up with the key way locations of the gears.
  4.  
  5. Slide both gears over their respective shafts and use a straight edge to confirm alignment.
  6.  
  7. Install the cup washer and camshaft bolt. Tighten the bolt to 35 ft. lbs. (47 Nm).
  8.  
  9. Check camshaft end-play. The specification with a new plate is 0.002-0.006 in. (0.051-0.052mm) and 0.002-0.010 in. (0.51-0.254mm) with a used plate. Replace the thrust plate if not within specifications.
  10.  
  11. Install the timing chain snubber.
  12.  
  13. Thoroughly clean and dry the gasket mating surfaces.
  14.  
  15. Install new O-rings to the block.
  16.  
  17. Remove the crankshaft oil seal from the cover. The seal must be removed from the cover when installing to ensure proper oil pump engagement.
  18.  
  19. Using a new gasket, install the chain case cover to the engine.
  20.  
  21. Make certain that the oil pump is engaged onto the crankshaft before proceeding, or severe engine damage will result. Install the attaching bolts and tighten to 20 ft. lbs. (27 Nm).
  22.  
  23. Use tool C-4992, or equivalent, to install the crankshaft oil seal. Install the crankshaft pulley using a 5.9 in. suitable bolt and thrust bearing and washer plate L-4524, or equivalent. Make sure the pulley bottoms out on the crankshaft seal diameter. Install the bolt and tighten to 40 ft. lbs. (54 Nm).
  24.  
  25. Install all other parts removed during the chain case cover removal procedure and fill the engine with oil.
  26.  
  27. Connect the negative battery cable, road test the vehicle and check for leaks.
  28.  

 
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