Chrysler Full-Size Trucks 1989-1996 Repair Guide

Timing Belt

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ADJUSTMENT



  1. Disconnect the negative battery.
  2.  
  3. Raise the vehicle and support safely. Remove the right front inner splash shield.
  4.  
  5. Remove the tensioner cover.
  6.  
  7. Place the special tensioning tool C-4703, or equivalent, on the hex of the tensioner so the weight is at about the 10 o'clock position and loosen the bolt.
  8.  
  9. The tensioner should drop down to the 9 o'clock position. Reposition the tool as required in order to have it end up at the 9 o'clock position (parallel to the ground, hanging to the left) plus or minus 15°.
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  11. Hold the tool in position and tighten the bolt. Do not pull the tool past the 9 o'clock position; this will make the belt too tight and will cause it to howl or possibly break.
  12.  
  13. Install the cover and the splash shield.
  14.  

REMOVAL & INSTALLATION



See Figures 1 and 2

If possible, position the engine so that the No. 1 piston is at TDC.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the timing belt covers.
  4.  
  5. Remove the timing belt tensioner and allow the belt to hang free.
  6.  
  7. Remove the air conditioning compressor belt idler pulley, if equipped and remove the mounting stud. Unbolt the compressor/alternator bracket and position it to the side.
  8.  
  9. Remove the timing belt from the vehicle.
  10.  

To install:
  1. Turn the crankshaft sprocket and intermediate shaft sprocket until the marks are in line. Use a straightedge shaft sprocket until the marks are in line. Use a straightedge from bolt to bolt to confirm alignment.
  2.  



Click image to see an enlarged view

Fig. Fig. 1: Align the crankshaft and intermediate shaft timing mark as indicated-2.5L engine

  1. Turn the camshaft until the small hole in the sprocket is at the top and rows on the hub are in line with the camshaft cap to cylinder head mounting lines. Use a mirror to see the alignment so it is viewed straight on and not at an angle from above. Install the belt, built let it hang free at this point.
  2.  



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the timing belt, sprockets, cover and seals-2.5L engine

  1. Install the air conditioning compressor/alternator bracket, idler pulley and motor mount. Remove the floor jack. Raise the vehicle and support safely. Have the tensioner at an arm's reach because the timing belt will have to be held in position with one hand.
  2.  
  3. To properly install the timing belt, reach up and engage it with the camshaft sprocket. Turn the intermediate shaft counterclockwise slightly, then engage the belt with the intermediate shaft sprocket. Hold the belt against the intermediate shaft sprocket and turn clockwise to take up all tension; if the timing marks are out of alignment, repeat until alignment is correct.
  4.  
  5. Using a 13mm wrench, turn the crankshaft sprocket counterclockwise slightly and wrap the belt around it. Turn the sprocket clockwise so there is no slack in the belt between sprockets, if the timing marks are out of alignment, repeat until alignment is correct.
  6.  

If the timing marks are in line but slack exists in the belt between either the camshaft and intermediate shaft sprockets or the intermediate and crankshaft sprockets, the timing will be incorrect when the belt is tensioned. All slack must be only between the crankshaft and camshaft sprockets.

  1. Install the tensioner and install the mounting bolt loosely. Place special tensioning tool C-4703, or equivalent, on the hex of the tensioner so the weight is at about the 9 o'clock position (parallel to the ground, hanging to the left) plus or minus 15°.
  2.  
  3. Hold the tool in position and tighten the bolt to 45 ft. lbs. (61 Nm). Do not pull the tool past the 9 o'clock position; this will make the belt too tight and will cause it to howl or possibly break.
  4.  
  5. Lower the vehicle and recheck the camshaft sprocket positioning. If it is correct install the timing belt covers and all related parts.
  6.  
  7. Connect the negative battery cable and road test the vehicle.
  8.  

 
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