Chrysler Front Wheel Drive Cars 4-CYL 1981-1995 Repair Information

Auxiliary (Intermediate or Silent) Shafts

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The 2.5L Premier engines are not equipped with auxiliary, intermediate, or silent shafts.

REMOVAL & INSTALLATION



2.2L and 2.5L Except Premier Engines
BALANCE SHAFTS

See Figures 1 through 6

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Fig. Fig. 1: Remove the balance shaft drive chain tensioner and guide by removing the attaching fasteners



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Fig. Fig. 2: After removing the drive chain, remove the balance shaft gear cover



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Fig. Fig. 3: Position the balance shafts so that their keyways are at the 12 o'clock position, then install the gears so that the timing marks are aligned as shown



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Fig. Fig. 4: Assemble the drive chain and 2 chain sprockets with the sprocket marks and plated chain links aligned as shown, then install on the engine



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Fig. Fig. 5: Install the balance shaft drive chain so that the timing marks are aligned as shown



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Fig. Fig. 6: Tension the balance shaft drive chain using the shim for correct adjustment

The 2.2L Turbo III and 2.5L engines are equipped with 2 balance shafts, mounted under the engine and in the oil pan, in addition to the intermediate shaft.

To complete this procedure, you will need Tool C-4916, or a shim 0.039 in. (1mm) thick and 2.75 in. (70mm) long.

  1. Drain and remove the oil pan, as described earlier in this section.
  2.  
  3. Remove the attaching bolts and remove the pick-up from the oil pump.
  4.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Remove the timing belt cover, belt, and crankshaft sprocket, as described earlier in this section. Remove the front crankshaft oil seal retainer, as described earlier in this section.
  2.  
  3. Remove its 3 mounting bolts and remove the chain cover.
  4.  
  5. Remove the mounting bolt from the chain guide and remove the guide from the engine block.
  6.  
  7. Remove the mounting bolt from the tensioner, then remove the tensioner unit.
  8.  
  9. Remove the bolts which retain the balance shaft gear and chain sprocket (the chain sprocket is retained by Torx® bolts). Remove both sprockets and the chain as an assembly.
  10.  
  11. Remove the gear cover retaining stud with a deep well socket. Then, remove the gear cover. Remove the gears from the shafts.
  12.  
  13. Unbolt and remove the carrier rear cover. Then, slide the balance shafts out of the carrier.
  14.  
  15. If it is necessary to remove the balance shaft carrier, remove the six carrier-to-crankcase attaching bolts and remove the carrier.
  16.  

To install:
  1. Clean all components and mating surfaces with a suitable solvent.
  2.  
  3. Installation the reverse of the removal order. Start by installing the carrier onto the crankcase and tightening the mounting bolts to 40 ft. lbs. (54 Nm).
  4.  
  5. Lubricate the bearing surfaces with clean engine oil, then install the shafts. Install the rear cover and tighten the bolts to 105 inch lbs. (12 Nm).
  6.  
  7. Turn both balance shafts until the keyways are parallel to the vertical centerline of the engine and above the shafts (12 o'clock position). Turn the timing gears so the timing marks align at the center point between the 2 shafts. Install the drive gear with the shorter hub onto the shaft which is driven by the crankshaft-to-balance shaft chain (the left shaft when viewing the front of the engine). Install the gear with the longer hub onto the other shaft (the right-hand one when viewing the engine from the front).
  8.  
  9. Install the gear cover and tighten the stud to 105 inch lbs. (12 Nm).
  10.  
  11. Install the crankshaft-to-balance shaft chain sprocket on the left-hand shaft, then tighten the Torx® bolts to 130 inch lbs. (14.5 Nm) Turn the crankshaft until the No. 1 cylinder is at Top Dead Center (TDC) on the compression stroke. The timing marks on the chain sprocket should line up with the parting line on the left side of No. 1 main bearing cap.
  12.  
  13. Place the chain over the crankshaft sprocket in such a way that the nickel plated link of the chain fits over the timing mark on the crankshaft sprocket.
  14.  
  15. Engage the balance shaft sprocket with the timing chain so that the yellow dot on the sprocket mates with the chain link that is painted yellow or nickel plated.
  16.  
  17. With both balance shaft keyways pointing up, slide the balance shaft sprocket onto the nose of the balance shaft. If necessary, push the nose of the balance shaft in slightly to allow the sprocket to clear the chain cover, when it is installed.
  18.  

The timing marks on the sprocket, the painted link, and the arrow on the side of the gear cover must all line up with their corresponding marks. If not, rearrange the shafts so that timing is correct, because improper timing will result in severe engine vibration!

  1. If the sprockets are all timed correctly, install the balance shaft bolts. Position a wooden block between the crankcase and a crankshaft counterweight to prevent rotation, then tighten the balance shaft bolts to 21 ft. lbs. (28 Nm).
  2.  
  3. Install the chain tensioner with bolts just finger tight.
  4.  
  5. Install Tool C-4916, or a shim 0.039 in. (1mm) thick and 2.75 in. (70mm) long between the tensioner and chain. Then, apply pressure to the tensioner directly behind the adjustment slot to push the tensioner and shim up against the chain. The shim must contact the shoe of the tensioner from the bottom almost all the way to the top and all slack must be removed.
  6.  
  7. Hold the tension and tighten the top tensioner bolt, then tighten the pivot bolt to 105 inch lbs. (12 Nm).
  8.  
  9. Remove the shim or tool.
  10.  
  11. Install the chain guide onto the double-ended stud. Make sure the tab on the guide fits into the slot on the gear cover. Install the nut and washer, then tighten the nut to 105 inch lbs. (12 Nm).
  12.  
  13. Install the carrier covers and tighten the bolts to 105 inch lbs. (12 Nm).
  14.  
  15. Install the oil seal retainer, crankshaft timing belt sprocket, timing belt and timing belt covers.
  16.  
  17. Install the oil pump pick-up and the oil pan.
  18.  


WARNING
Do NOT start the engine without first filling the engine with clean engine oil.

  1. Fill the engine with the proper type and amount of engine oil. For more details, refer to Routine Maintenance .
  2.  
  3. Connect the negative battery cable.
  4.  

INTERMEDIATE SHAFT

See Figures 7 through 11

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Fig. Fig. 7: Use the tools shown to hold the intermediate shaft sprocket stable while loosening the attaching bolt



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Fig. Fig. 8: Unbolt the intermediate shaft retainer from the engine block



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Fig. Fig. 9: Form a gasket for the intermediate shaft retainer using Mopar® Gasket Maker, as shown



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Fig. Fig. 10: Use the tools shown to remove and install the front intermediate shaft bushing



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Fig. Fig. 11: Remove and install the rear intermediate shaft bushing with tools C-4686-2 and C-4686-1, or their equivalents

  1. Disconnect the negative battery cable.
  2.  
  3. Rotate the crankshaft so that the No. 1 piston is at Top Dead Center (TDC) of its compression stroke.
  4.  
  5. Remove the timing belt covers to confirm that all timing marks on the camshaft, crankshaft and intermediate sprockets are aligned with the engine block timing marks.
  6.  
  7. Remove the distributor, if equipped. Looking down the distributor shaft at the oil pump, make sure that the slot in the shaft is parallel with the center line of the engine block (runs the same direction as the crankshaft).
  8.  
  9. Remove the oil pan and oil pump.
  10.  
  11. Remove the timing belt, as described earlier in this section.
  12.  
  13. Remove the intermediate shaft sprocket.
  14.  
  15. Remove the shaft retainer bolts and remove the retainer from the engine block.
  16.  
  17. Slide the intermediate shaft out of the engine.
  18.  
  19. If necessary, remove the front bushing using Chrysler Tool C-4697-2, or equivalent, and the rear bushing using Chrysler Tool C-4686-2, or equivalent.
  20.  

To install:
  1. Clean all components and mating surfaces of dirt, grease and grime.
  2.  
  3. Install the front bushing using Tool C-4697-1, or equivalent, until the tool is flush with the engine block. Install the rear bushing using tool C-4686-1, or equivalent, also until the tool is flush with the block.
  4.  
  5. Lubricate the distributor drive gear, if equipped, then install the intermediate shaft into the engine block.
  6.  
  7. Install a new seal in the retainer and apply silicone sealer to the mating surface of the retainer. Install the retainer onto the engine block, then tighten the bolts to 105 inch lbs. (12 Nm).
  8.  
  9. Install the intermediate shaft sprocket, the timing belt and the timing belt covers, as described earlier.
  10.  
  11. With the timing belt properly installed, install the oil pump so the slot is parallel to the center line of the crankshaft. If equipped, install the distributor so that the rotor is aligned with the No. 1 spark plug wire tower on the cap.
  12.  
  13. Fill the engine with the proper amount and type of engine oil. Refer to Routine Maintenance for more details.
  14.  


WARNING
Do NOT start the engine without first filling the engine with clean engine oil.

  1. Connect the negative battery cable.
  2.  
  3. Start the engine, check for leaks and adjust the ignition timing, as required.
  4.  

2.6L Engine

See Figures 12 through 15

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Fig. Fig. 12: Cross-section view of the oil pump and lower silent shaft assembly



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Fig. Fig. 13: Remove and install the silent shaft bearings with Tools MD998250 and MD998251, as shown



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Fig. Fig. 14: Exploded view of the left silent shaft



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Fig. Fig. 15: Cross-section view of installing the thrust plate with 2 alignment dowels fabricated from 2 old bolts

The 2.6L engines are equipped with 2 silent shafts, one of which drives the oil pump.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the timing chain cover and timing chains, as described earlier in this section.
  4.  
  5. Remove the sleeve from the oil pump. Remove the oil pump by first removing the bolt locking the oil pump driven gear and the right silent shaft, then remove the oil pump mounting bolts.
  6.  
  7. Slide the silent shaft out of the engine block.
  8.  

If the bolt locking the oil pump and the silent shaft is difficult to loosen, remove the oil pump and the shaft as a unit.

  1. Remove the left silent shaft thrust washer and slide the shaft out of the engine block.
  2.  

To install:
  1. Install the right silent shaft into the engine block.
  2.  
  3. Install the oil pump assembly onto the engine block. Do not lose the woodruff key from the end of the silent shaft. Tighten the oil pump mounting bolts to 73-85 inch lbs. (8.2-9.5 Nm).
  4.  
  5. Tighten the silent shaft and oil pump driven gear mounting bolt.
  6.  

The silent shaft and the oil pump can be installed as a unit, if necessary.

  1. Install the left silent shaft into the engine block.
  2.  
  3. Install a new O-ring on the thrust plate and install the unit into the engine block, using a pair of bolts without heads, as alignment guides.
  4.  


CAUTION
If the thrust plate is turned to align the bolt holes, the O-ring may be damaged.

  1. Remove the guide bolts and install the regular bolts into the thrust plate and tighten securely.
  2.  
  3. Install the timing chains and timing chain cover, as described earlier in this section.
  4.  
  5. Fill the engine with the proper amount and type of engine oil, if the engine oil was drained during the removal procedure. For more details, refer to Routine Maintenance .
  6.  


WARNING
Do not start the engine without first filling it with clean engine oil.

  1. Connect the negative battery cable.
  2.  

 
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